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Amarok 2.0 Biturbo Preventiva PDF
Amarok 2.0 Biturbo Preventiva PDF
Maintenance
Amarok 2011 ➤
Edition 10.2012 agen
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Heading
1. Engine list
2. General rules of cleanliness
3. Service work
4. General
5. Descriptions of work
6. Exhaust emissions test
7. Glossary
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Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
Contents
1 Engine list . . . . . . . . . . . . . . . . . . . w. a.g.en. A. G. ..V.o.lk.sw. a.g.e.n .AG
. .do. e.s. . . . . . . . . . . . . . . . . . . . . . . . 1
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2 General rules of cleanliness ed.by. V. . . . . . . . . . . . . . . . . . . . . . . . t.g.ua. ra. . . . . . . . . . . . . . . . . . . 3
ris nte
2.1 Rules of cleanliness during tho work with information material “Maintenance e o Manual” . . . . . . 3
u r
2.2 Rules of cleanliness during ss
a work with information material “Maintenance aManual” c ...... 10
2.3 Rules of cleanliness during work with information material “Maintenance Manual” . . . . . . 16
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2.4 Rules of cleanliness during work with information material “Maintenance Manual” . . . . . . 17
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2.5 rm
Rules of cleanliness during work with information material “Maintenance manual for heating,
ab
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ventilation and air conditioning system” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
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2.6 Rules of cleanliness during work with information material “Maintenance Manual - Body”
h re
........................................................................ 28
hole
spec
2.7 Rules of cleanliness during work with information material “Maintenance Manual - Body”
es, in part or in w
........................................................................ 35
t to the co
3 Service work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3.1 Information reference flexible or fixed service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
rrectness of i
3.2 Service tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
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4.3 Severe operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
n in
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4.5 Countries with high levels of dust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
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cum
4.6 Sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
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4.7 Entries in service schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
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5 Descriptions of work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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5.1 Lifting the vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
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5.2 Swivel joints: Visual check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
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5.29 s Resetting programmed values in engine control unit .............................. 121
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5.31 Engine oil: Drain or extract; renew oil filter and replenish engine oil . . . . . . . . . . . . . . . . . . 122
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5.32 Engine and components in engine compartment (from above and below): Perform visual
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5.33 Bonnet catch: Clean, ensure attachment is secure and lubricate . . . . . . . . . . . . . . . . . . . . 127
hole
spec
5.34 Check breakdown set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
es, in part or in w
t to the co
5.36 Wheel securing bolts: Tighten to specified torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
5.37 Reading radio code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
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5.38 Radio / radio navigation system: Enter anti-theft coding PIN . . . . . . . . . . . . . . . . . . . . . . . . 133
5.39 Radio navigation system: Insert navigation CD/DVD and perform update . . . . . . . . . . . . . . 134
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........................................................................ 134
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5.42 Windscreen wiper blades: Check park position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
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5.45 Service interval display: Adapt (export) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
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5.46 Track rod ends: Check clearance, security and boots . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
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5.47 Power assisted steering: Check fluid level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
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5.48 Doors: Grease door arrester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
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5.49 Paint: Perform visual check for damage and corrosion, interior and exterior when doors and
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bonnet/rear lid/flaps are open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Prote AG.
ii Contents
Amarok 2011 ➤
Maintenance - Edition 10.2012
1 Engine list
(VIGG000558; Edition 10.2012)
Diesel engines ⇒ page 1
Petrol engines ⇒ page 1
Diesel engines
Note
To ease the search for an engine, the engine codes are listed in
alphabetical order.
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Camshaft drive Toothed belt Toothed belt Toothed Toothed Toothed belt Toothed
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Engines: ⇒ Petrol
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Capacity I 2.0
Introduction Week 42/2010 ►
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Bore ∅ mm 82.5
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1. Engine list
Amarok 2011 ➤
Maintenance - Edition 10.2012
Engines: ⇒ Petrol
Capacity I 2.0
Introduction Week 42/2010 ►
Engine code CFPA
Camshaft drive Chain
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2 1. Engine list
Amarok 2011 ➤
Maintenance - Edition 10.2012
Note
Only some examples are given in this document. Not all concrete
situations are covered.
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⇒ “2.1 Rules of cleanliness during work with information material
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Maintenance Manual ”, page 16
⇒ “2.4 Rules of cleanliness during work with information material
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Maintenance Manual ”, page 17
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Special tools and workshop equipment required
♦ Universal cloth -VAS 6385-
♦ Non-fibrous lint-free cloths
♦ Soft commercially available sponge
♦ Commercially available wire brush (brass or plastic)
♦ Commercially available vacuum cleaner
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Cleaning fuel filter housing ⇒ page 7
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unit ⇒ page 8
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Cleaning filler neck of reducing-agent tank ⇒ page 8
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Cleaning rear door hinges ⇒ page 8
Cleaning holes for checking and draining in manual gearbox
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⇒ page 9
Cleaning spray jets for headlight cleaning system ⇒ page 9
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Cleaning dust and pollen filter housing ⇒ page 9
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Cleaning holes for filling and draining in transfer box
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⇒ page 9
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lint-free cloth or the universal cloth -VAS 6385- , then push
dipstick back in as far as it will go.
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– Remove all dirt and dust from the seals of the sliding window op
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example universal cloth -VAS 6385- ) and normal rinsing wa‐
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2.1.7 Cleaning guide rails of sliding sunroof
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– Clean guide rails of sliding sunroof -arrows- with a non-fibrous,
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After cleaning the guide rails, lubricate them again with grease - Prote AG.
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2.1.9 Cleaning holes for filling and draining in ss c
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– Clean surroundings of oil filler plug -1- and oil drainage plug
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– Cover magnet of oil drainage plug with a non-fibrous, lint-free
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Note
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Observe disposal regulations!
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2.1.10 Cleaning fuel filter housing and fuel filter
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– Remove dirt from fuel filter housing and fuel filter connections
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with a non-fibrous, lint-free cloth (for example universal cloth
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-VAS 6385- ), if necessary using a wire brush as well (brass
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– Cover surroundings of fuel filter connections with a non-fi‐
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brous, lint-free cloth (for example universal cloth -VAS 6385- ).
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Note
Note
♦ Before blowing out the air filter housing with compressed air,
cover components that conduct air such as the air mass meter,
air inlet pipes etc. with a clean cloth or with blue blotting paper
in order to prevent malfunctions.
♦ When replacing air filter, make sure that no dirt gets into intake
hose, air mass meter -G70- and air filter cover.
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Amarok 2011 ➤
Maintenance - Edition 10.2012
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2.1.21 Cleaning water drain hole in floor area
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– Remove dirt from water drain holes -2- with a commercially
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– Dry the fuel pressure sender -G247- .
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– Unscrew and remove fuel pressure sender -G247- -1-.
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Seal the high-pressure accumulator hole immediately with a suit‐
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2.2.4 Cleaning work on air mass meter -G70-
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– Check intake port for dirt as far as the air filter element.
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– If there is any salt residue, dirt or leaves in the air filter housing,
wash the housing out with a non-fibrous, lint-free cloth (for ex‐
ample universal cloth -VAS 6385- ) or vacuum cleaner.
Note
♦ Do not allow dirt to get into the hole of the high-pressure ac‐
cumulator (fuel rail) in any circumstances.
♦ Do not allow any cleaning agent to get into the connector at
the fuel pressure regulating valve -N276- .
Note
Coking can occur in the housing of the throttle valve due to the
interplay of unfavourable factors. If coking is discovered, e.g. dur‐
ing removal of the exhaust gas recirculation valve -N18- or the
motor for the intake manifold flap -V157,- , the housing has to be
cleaned.
WARNING
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– Remove throttle valve module -J338- . cop Vo
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2.2.12 Cleaning work on a used injector (piezo
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injector)
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Clean the sealing surface of the injectors (piezo injectors) in the
cylinder head and the injector shaft.
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– Use a clean cloth soaked in diesel fuel or rust remover to re‐
move soot particles on the sealing surface.
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– Remove rough dirt in the glow plug channel in the cylinder
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head with the help of a vacuum cleaner.
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– Spray brake cleaner into the glow plug channel in the cylinder
head or spray a suitable cleaning agent into the glow plug
channel.
– After allowing cleaner to work in, blow out with compressed
air.
– Then, clean glow plug channel with a a non-fibrous, lint-free
cloth moistened with oil (for example universal cloth -VAS
6385- ).
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Do not allow tyre sealant to come into contact with eyes or skin!
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– Using a suitable drill or cutter, carefully make a hole in the
shoulder area of the tyre.
– Hold wheel over drip tray and allow sealant to flow out.
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– Remove tyre from wheel rim.
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– Clean wheel rim with a damp cloth, for example.
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♦ Make sure that the tyre and the tyre pressure sensor do not
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touch each other during removal or assembly work.
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not come into contact with water or are blown out with com‐
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2.3.4 Cleaning work on brake system
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WARNING
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Before undoing connections, clean them and their surround‐
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ings on the anti-blocking system thoroughly but do not use any
inform
aggressive cleaning agents such as brake cleaner, petrol, di‐
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The contact surface of the rain sensor within the locking ring on
the windscreen must be free of dirt, dust and grease.
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Do not use rust remover, orise
contact spray or grease etc. as the nte
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specified torque swillau be exceeded during tightening due to a lack r ac
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of static friction in
s the thread and will cause the threaded connec‐
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erm
ab
– Disconnect battery.
ility
ot p
wit
, is n
h re
sion or dirt.
hole
spec
– Clean the battery terminal clamp with the wire brush of the
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
– Clean the battery terminal with the bottom of the battery ter‐
for
en
g
t.
yi Co
Cop py
– Reconnect battery and secure the battery terminals by tight‐
t. rig
gh ht
yri
ening them to the specified torque.
p by
o Vo
by c lksw
cted agen
Prote AG.
Note
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
♦ A/C service station with rinsing device -VAS 6337-
es, in part or in w
t to the co
♦ Adapter case, car kit, VW/Audi -VAS 6338/1-
♦ Adapter case, commercial vehicle kit -VAS 6338/50-
rrectness of i
♦ Torque wrench -V.A.G 1783-
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
♦ Brass wire brush (commercially available)
Prote AG.
ce
e
nl
pt
1538- and spraying lance ⇒ page 27
du
an
itte
y li
Cleaning work on heat exchanger ⇒ page 27
erm
ab
ility
ot p
wit
, is n
h re
ic “DW5S”
hole
spec
es, in part or in w
t to the co
Note
rrectness of i
♦ The seal (sealing film) is self-adhesive. It protects the heater
and its electronic components against the unallowed ingress
l purpos
of water.
♦ The seal (sealing film) is to be re-attached after any repair work
nf
ercia
o
and must not left off under any circumstances! For spare part,
rm
see ⇒ Electronic parts catalogue (ETKA) .
m
atio
om
n in
c
thi
and adhesive residue from bonding surfaces with silicone re‐
te
sd
a
o
r
rp
cu
o
m
f
en
ng
t.
– Pull the seal (sealing film) -1- off the heater.
yi Co
Cop py
t. rig
– Clean bonding surfaces with silicone remover -LLS MAX 007- .
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
WARNING
Note
Note
above, you can also rinse the refrigerant circuit with the A/C
un
pt
an
d
y li
ab
pe
ility
h re
spec
t to the co
a
com
tion in
Preparatory work
r
te o
thi
s
iva
do
cum
fo
t.
yi
tioning system .
Co
Cop py
t. rig
gh ht
In the case of a vehicle with throttle and collecting receptacle. yri
p by
co Vo
by lksw
cted
– Remove throttle (vehicle-specific) and connect refrigerant
agen
Prote AG.
pipes to each other again ⇒ Heating, air-conditioning system .
ce
e
nl
pt
du
an
itte
y li
erm
Note
ab
ility
ot p
wit
, is n
h re
interior volume, it takes up too much liquid refrigerant. If this re‐
hole
spec
frigerant is vacuum-extracted, the connecting receptacle freezes
es, in part or in w
t to the co
ger.
rrectness of i
– Remove fluid container ⇒ Heating, air-conditioning system
l purpos
nform
ercia
at
– Remove expansion valve ⇒ Heating, air-conditioning system
om
io
(vehicle-specific) and replace it with an adapter.
n
c
in t
or
his
ate
do
priv
c
Note
um
for
en
ng
t.
yi Co
If a suitable adapter for the expansion valve is not contained in Cop py
. rig
the adapter case, car kit, VW/Audi -VAS 6338/1- or adapter case,
ht ht
rig by
py
commercial vehicle kit -VAS 6338/50- , the removed expansion co Vo
by lksw
valve can also be drilled open (the old expansion valve is to be cted agen
Prote AG.
replaced with a new one).
Caution
Note
Note
In the case of vehicles with 2 evaporators, the circuit for the sec‐
ond evaporator is to be detached from the circuit of the first
evaporator and then rinsed in a separate step ⇒ Heating, air-
conditioning system .
Rinsing
– Check the amount of refrigerant in the refrigerant bottle; it must
contain at least 7 kg of R134a refrigerant.
Note
AG. Volkswagen AG d
agen oes
olksw not
If necessary, eswitch
db
y V on the heater fitted to your refrigerant
gu
ara bottle
for 30 minutes
horis
before you start rinsing. This causes the
nte
epressure
in the refrigerant
sa
ut bottle to increase and speeds up filling oof r a the
c
rinsing circuit.
s
ce
e
nl
pt
du
an
itte
ab
ility
wit
h re
diameter).
spec
es, in part or in w
t to the co
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Note
ce
e
nl
pt
device for refrigerant circuits.
du
an
itte
y li
♦ The filter in the rinsing device for refrigerant circuits is to be
erm
ab
ility
replaced after 2 rinsing cycles at the latest (rinsed vehicle),
ot p
wit
, is n
h re
rinsed refrigerant circuit. If a severely contaminated refrigerant
hole
spec
black or viscous or there are a lot of filings in the refrigerant
es, in part or in w
t to the co
circuit), the filter is to be replaced after the refrigerant circuit is
rinsed. In the case of a refrigerant circuit that is so contami‐
nated, it is also useful to rinse the refrigerant circuit again after
rrectness of i
the filter has been changed.
l purpos
nf
ercia
orm
then rinse the refrigerant circuit again with another rinsing run
m
atio
m
n in
or c
thi
♦ Liquid refrigerant cannot be pumped through the expansion
te
sd
a
valve, the throttle and the dessicant bag of certain liquid con‐
iv
o
r
rp
m
f
en
t.
yi Co
air-conditioning system . t. Cop py
rig
gh ht
♦ Adapter for connecting the A/C service station and for bridging pyri by
Vo
co
certain components in the refrigerant circuit.
by lksw
cted agen
Prote AG.
Note
ce
le
pt
an
d
be ignored).
itte
y li
erm
ab
♦ If the circuit is very dirty, it may be necessary to carry out two
ility
ot p
wit
is n
rinsing runs). Before the second rinsing cycle, the filter of the
h re
ole,
spec
urposes, in part or in wh
t to the co
Sequence of steps in a rinsing run (these steps are carried out
automatically in accordance with the program of the A/C service
station)
rrectne
♦ After the station is switched on, the rinsing circuit (refrigerant
circuit with connecting hoses and the rinsing device for refrig‐
ss
erant circuits) is first evacuated, whereby the refrigerant circuit
o
cial p
f
is checked for leaks at the same time. It may be necessary to
inform
start the next steps manually, depending on the type of A/C
mer
service station.
atio
om
n
c
i
or
n thi
into the evacuated rinsing circuit via the high-pressure side of
te
sd
va
o
pr
cum
normal during operation of the air-conditioning system) and
r
fo
en
ng
ce
e
nl
pt
du
an
itte
y li
erm
ab
cessitates such replacement ⇒ Heating, air-conditioning sys‐
ility
ot p
wit
oil from the removed air-conditioning compressor (replace
, is n
h re
components of refrigerant circuit) and refill the circuit with the
hole
spec
specified amount of fresh refrigerant oil ⇒ Vehicle-specific re‐
es, in part or in w
pair manual .
t to the co
Note
rrectness of i
l purpos
nf
ercia
orm
already in the circuit ⇒ Vehicle-specific repair manual
m
atio
om
n in
♦ If the air-conditioning compressor does not need to be re‐
or c
thi
te
sd
a
o
r
rp
cu
bed (tip out refrigerant oil and fill the air-conditioning
o
m
f
t.
yi
amount) (replace components of the refrigerant circuit) and
Co
Cop py
the ⇒ vehicle-specific repair manual .
t. rig
gh ht
pyri by
Vo
co lksw
by
cted
– Re-assemble the refrigerant circuit completely ⇒ Heating, air-
agen
Prote AG.
conditioning system .
– Evacuate and fill the refrigerant circuit as prescribed.
– Start up the air-conditioning system as prescribed ⇒ Heating,
air-conditioning system .
ce
le
un
pt
an
d
ing lance
itte
y li
rm
ab
pe
ility
The evaporator is directly sprayed with “Contra Sept” with the help
ot
wit
of a spraying lance (approx. 10 bar).
, is n
h re
hole
spec
es, in part or in w
Note
t to the co
“Contra Sept” neutralises dirt in the form of microbes and bacteria
directly on the evaporator.
rrectness of i
l purpos
nform
ercia
a
com
ti
a set of vehicle-specific user instructions.
on in
r
te o
thi
Current devices and spraying lances can be found in ⇒ Service‐ s
iva
cum
fo
t.
yi Co
Cop py
t. rig
gh ht
yri
WARNING
p by
co Vo
by lksw
cted agen
Prote AG.
Danger of freezing injuries.
If refrigerant circuit has not been evacuated, refrigerant can
escape.
Extract refrigerant before opening refrigerant circuit.
Note
Before installing the heat exchanger, check the foam base -1- and
the all-round seal of the roof air-conditioning system -2- for dam‐
age and looseness. If necessary, replace them.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
2.6 Rules of cleanliness during work with in‐
erm
ab
ility
ot p
ual - Body”
h re
ole,
spec
urposes, in part or in wh
f in
i
or
⇒ page 29
thi
te
sd
va
o
pr
cum
r
fo
en
ng
Cleaning work on the retaining plate for the interior mirror with rain
t.
yi Co
sensor ⇒ page 29 Cop py
t. rig
gh ht
yri
Cleaning work on the side window ⇒ page 30 p by
co Vo
by lksw
cted agen
Cleaning work on door outer seal ⇒ page 30 Prote AG.
Cleaning work if a mirror base has fallen off or if new mirror base
is to be fitted ⇒ page 30
Cleaning work when a hard top is to be fitted ⇒ page 30
Cleaning work before renewal of emblems etc. ⇒ page 31
Cleaning work before replacement of protective film (transparent)
⇒ page 31
Cleaning water drainage hoses (Polo Classic) ⇒ page 32
Cleaning water drainage hoses (Polo Variant) ⇒ page 33
Cleaning water drainage hoses (Transporter) ⇒ page 33
WARNING
ce
le
un
pt
10- .
an
d
itte
y li
erm
ab
– Allow adhesive sealing material of plastic trim to harden (ap‐
ility
ot p
wit
is n
h re
– Clean surface of outer panel with adhesive remover -D 002
ole,
spec
urposes, in part or in wh
fully remover dirt, grease, wax and other impurities with plastic
t to the co
cleaner -D 195 850 A1- .
– Clean the painted surface roughly with a dry cloth.
rrectne
– Remove residual dirt, using adhesive remover -D 002 000 10- .
ss o
cial p
f in
– Clean the viewing window -arrow- of the windscreen -1- from
form
mer
atio
m
n
c
i
or
n
with the cleaning solution -D 009 401 04- .
thi
te
sd
va
o
pr
cum
r
fo
en
ng
t.
yi
WARNING
Co
Cop py
t. rig
gh ht
yri by
The ceramic coating on the glass is not a primer. The glass cop Vo
by lksw
must be primed before the adhesive sealing material is applied.
cted agen
Prote AG.
Only use glass/paint primer D 009 200 02!
Note
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Clean the bonding surface all round with the adhesive remover
-D 002 000 10- and then dry the bonding surface with a cloth.
rrectness of i
Note
l purpos
nf
ercia
orm
2.6.7 Cleaning work if a mirror base has fallen
m
atio
om
n in
or c
thi
te
sd
a
o
r
rp
cu
mirror base has fallen off).
o
m
f
en
ng
t.
yi
– Wet-grind the bonding surface with very fine emery paper (800
Co
op py
to 1200 grain) until the bonding surface is covered with a fine t. C rig
gh ht
layer of water. yri
p by
o Vo
by c lksw
cted
– Then, clean bonding surface with cleaning solution D 009 401
agen
Prote AG.
04.
AG. Volkswagen AG d
agen oes
Note Volksw not
gu
by ara
d
rise nte
♦ Bonding surfaces must
utho be free of dust, grease, dirt and other eo
ra
media and mustssbe
a dry. c
ce
le
♦ First, pull protective film off the preliminary seal directly before
un
pt
an
d
fitting.
itte
y li
rm
ab
pe
ility
wit
, is n
h re
spec
es, in part or in w
t to the co
Note
rrectness of i
tion in
r
te o
thi
– Heat protective film with a hot-air blower -V.A.G 1416- and pull
s
iva
do
cum
fo
en
– Clean outer panel with petroleum ether, then treat it with sili‐
ng
t.
yi Co
cone remover and dry with a cloth. t. Cop py
rig
gh ht
• Bonding surfaces must be free of dust and grease. pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Spray a thin film of soapy water onto the surface of the outer
panel, using a spray bottle.
– Pull backing of the bonding surface off the protective film.
– Apply and align protective film.
– Push out the water under the film, using a plastic wiping blade
with a paper tissue wrapped around it.
Note
The paper tissue is needed to ensure that the hard edge of the
plastic wiping blade does not scratch the film.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
The water drainage hoses at the front -1- are routed through or
s
iva
do
cum
en
ng
t.
yi Co
The water drainage hoses at the rear -2- are routed through the Cop py
t. rig
D-pillars and end behind the bumper cover. Cleaning is carried yri
gh by
ht
out from the lower end of the hoses. The bumper or the luggage op Vo
by c lksw
compartment trim must be removed for this. cted agen
Prote AG.
Note
Note
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
The water drainage hoses at the rear are routed through the D-
pillars and end in the rear wheel housings. Cleaning is carried out
from the wheel housing and, to do this, the wheel housing liner
must be removed.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
io
Note
n
c
in t
or
his
ate
en
ng
t.
yi Co
op
2.7 Rules of cleanliness during work with in‐
C py
t. rig
gh ht
yri
formation material “Maintenance Man‐
p by
o Vo
by c lksw
cted agen
ual - Body”
Prote AG.
ce
Cleaning ATF lines and ATF cooler ⇒ page 36 e
nl
pt
du
an
itte
y li
erm
ab
ility
Cleaning work on the clutch ⇒ page 37
ot p
wit
, is n
h re
hole
spec
2.7.1 Cleaning ATF lines and ATF cooler
es, in part or in w
t to the co
If the ATF is contaminated, blow out the engine oil cooler and ATF
lines with compressed air (max. 10 bar) before installing the gear‐
box or installing a replacement gearbox.
rrectness of i
l purpos
WARNING
nf
ercia
orm
m
atio
om
n in
or c
– Unscrew and remove the nuts of the ATF lines and pull ATF
thi
e
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Remove the ATF lines -1- off the ATF cooler. When doing this,
counterhold on the connecting piece -2-.
– Attach a hose to the ATF line and secure with a hose clip.
Place the other end of the hose in a suitable container.
– Blow out ATF line with compressed air.
– Attach hose to other ATF line and repeat the procedure.
Note
Note
Note
Clean splines of drive shaft and, if the clutch plate has been used,
clean the splines of the hub. Remove corrosion and apply a very
thin layer of lubricating grease for male splines of clutch plates -
G 000 100- to the splines. Then, move the clutch plate back and
forth on the drive shaft until the hub moves easily on the shaft.
Remove excess grease.
Note
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
3 Service work
This chapter provides information on the following subjects:
♦ Information reference flexible or fixed service ⇒ page 38
AG. Volkswagen AG d
agen oes
♦ Service tables ⇒ page 40 olksw not
byV gu
ara
ed
♦ Scopes of service ⇒ page 50 horis nte
eo
aut ra
3.1 Information reference flexible or fixed ss c
ce
le
service
un
pt
an
d
itte
y li
erm
ab
Service identification ⇒ page 38
ility
ot p
Flexible service ⇒ page 38
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
3.1.1 Service identification
rrectne
– Referring to vehicle data sticker ⇒ page 59 , check if vehicle
is equipped with following PR numbers:
ss
The PR number is decisive for the service intervals
o
cial p
f
⇒ page 40 .
inform
mer
atio
om
n
c
i
or
n thi
e
sd
iva
o
pr
c
2013 ► QI6 Flexible service
um
r
fo
en
ng
t.
2013 ► QI8 Flexible service
yi Co
Cop py
2013 ► QI1, QI2, QI3, QI4, QI5, QI7 Fixed service
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Note
38 3. Service work
Amarok 2011 ➤
Maintenance - Edition 10.2012
pt
du
y li
ice) ⇒ page 39
erm
ab
ility
ot p
⇒ page 40
h re
hole
spec
t to the co
ice)
at
om
ion
c
his
ate
en
g
t.
yi Co
filter are evaluated by the control unit. t. Cop py
rig
gh ht
pyri by
Vo
co lksw
by
39
cted agen
Prote AG.
3. Service work
Amarok 2011 ➤
Maintenance - Edition 10.2012
Note
For vehicles with a flexible service but which are serviced ac‐
cording to fixed service intervals, the service interval display must
be recoded to “non-flexible” ⇒ page 143 .
pt
Note
du
an
itte
y li
erm
ab
occurs first.
wit
, is n
h re
spec
service inspection.
♦ It is also possible, to perform additional work outside the serv‐
rrectness of i
at
om
ion
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
40 3. Service work
Amarok 2011 ➤
agen
AG. Volkswagen AG d
oes
Maintenance - Edition 10.2012
olksw not
yV gu
Service intervalsrised b ara
nte
ho eo
aut ra
s
s Caution c
ce
e
nl
pt
du
an
itte
y li
erm
ab
• Some countries have an elevated sulphur content in diesel
ility
ot p
fuel.
wit
, is n
h re
hole
spec
inders and it considerably reduces the cleanliness of pis‐
es, in part or in w
tons.
t to the co
♦ Therefore, in those countries with an elevated sulphur
content in diesel fuel, change the engine oil every 5,000
rrectness of i
km.
l purpos
nf
ercia
o
Note
rm
m
atio
om
n in
However, other intervals apply for other countries. Your importer
or c
thi
te
sd
iva
o
r
rp
cu
o
m
Amarok 2010 ►
f
en
ng
t.
yi Co
ht. Cop
Service interval 2010 ►2012 py
rig
From to Engine/ Service: Indication on SID
rig ht
py by
o Vo
Engine code/ Intervals (with oil change)
by c lksw
cted agen
Prote
PR No./Remarks
AG.
2010 ▶ Diesel engines with high Oil change service (fixed): YES
2012 sulphur content in diesel every 10,000 km or 1 year
fuel
QG0/QG2 or QG1 vehicles Oil change service (fixed): YES
coded to fixed intervals every 15,000 km or 1 year (petrol en‐
gine)
Oil change service (fixed): YES
every 20,000 km or 1 year (diesel en‐
gine)
Interval service (fixed): YES
max. 30,000 km or 2 years (petrol en‐
gine)
Interval service (fixed): YES
max. 40,000 km or 2 years (diesel en‐
gine)
QG1 vehicles Interval service (flexible): YES
max. 30,000 km or 2 years (petrol en‐
gine)
Interval service (flexible): YES
max. 40,000 km or 2 years (diesel en‐
gine)
All vehicles First inspection service after NO
3 years, then every 2 years
3. Service work 41
Amarok 2011 ➤
Maintenance - Edition 10.2012
Amarok 2013►
Service intervals 2013►
From - to PR No. Service: Indication on SID
Intervals (with oil change)
2013► QI1 Oil change service (fixed): YES
every 5,000 km or 1 year
QI2 Oil change service (fixed): YES
every 7,500 km or 1 year
QI3 Oil change service (fixed): YES
every 10,000 km or 1 year
QI4 Oil change service (fixed): YES
every 15,000 km or 1 year
QI5 Oil change service (fixed): YES
every 20,000 km or 1 year
QI7 Oil change service (fixed): YES
every 10,000 mi or 1 year
QI1, QI2, QI3, QI4, QI5, QI7 Interval service (fixed): YES
every 30,000 km or 2 years (petrol
engine)
QI1, QI2, QI3, QI4, QI5, QI7 Interval service (fixed): YES
every 40,000 km or 2 years (diesel
engine)
QI6 Interval service (flexible): YES
every 30,000 km or 2 years (petrol
engine)
QI8 AG. Volkswagen AG d
Interval
agen service (flexible):oes YES
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V every 40,000 km or 2 yearsot (diesel
ol n
by gu
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d engine) ara
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QI1, QI2, QI3, QI4,
s aut
QI5, First inspection service after ra
c
NO
QI6, QI7, QI8 s 3 years, then every 2 years
ce
le
un
pt
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ab
ility
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Note
is n
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ole,
spec
curs first.
t to the co
Caution
ss o
cial p
n
c
i
or
n thi
te
sd
a
Amarok
iv
o
pr
cum
r
en
ng
t.
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With flexible service t. Cop
With fixed service
py
rig
gh
PETROL ENGINE
ht
pyri by
Vo
co lksw
by
4-cylinder 504 00 cted 4-cylinder 504 001)
agen
Prote AG.
alternative 503 00 502 00 2)
DIESEL ENGINES
42 3. Service work
Amarok 2011 ➤
Maintenance - Edition 10.2012
Amarok
VW ENGINE OIL STANDARDS
4-cylinder 507 00 1) 4-cylinder 507 00 1)
(with Bosch EDC 17 505 01 2) (with Bosch EDC 17 505 012)
TDI common rail with die‐ TDI common rail with die‐
sel particulate filter) sel particulate filter)
4-cylinder 507 00 1) 4-cylinder 507 00 1)
(with Bosch EDC 17 505 012) (with Bosch EDC 17 505 012)
TDI common rail without TDI common rail without
diesel particulate filter) diesel particulate filter)
ce
le
pt
commercial vehicles for markets with individual maintenance re‐
an
d
itte
y li
quirements that differ from the German market due to the more
erm
ab
difficult vehicle operating conditions in those markets.
ility
ot p
wit
is n
h re
ole,
Caution
spec
urposes, in part or in wh
t to the co
Only applies to diesel engines!
♦ In some regions, the sulphur content is relatively high.
rrectne
km.
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
Note
um
r
fo
en
ng
t.
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op
♦ Depending on the conditions of use and the vehicle's equip‐ C py
ht. rig
ment, extra service work must be performed in addition to the rig ht
py by
inspection service or oil change service.
co Vo
by lksw
cted agen
Prote AG.
♦ To ensure that every service is carried out at the right time and
that no service is forgotten, a service sticker on the door pillar
or the service interval indicator on the display of the dash panel
insert serves as a reminder.
♦ For combined kilometre and time display applies: whichever
occurs first.
3. Service work 43
Amarok 2011 ➤
Maintenance - Edition 10.2012
Amarok 2010 ►
Service interval 2010 ►2012
From to Engine/ Service: Indication on SID
Engine code/ Intervals (with oil change)
PR No./Remarks
2010 ▶ Diesel engines with high Oil change service depending on sul‐ YES
2012 sulphur content in diesel phur content in fuel ⇒ page 45
fuel
QG0/QG2 or QG1 vehicles Oil change service (fixed): YES
coded to fixed intervals, ex‐ every 15,000 km or 1 year (petrol en‐
port gine)
Interval service (fixed): YES
max. 30,000 km or 2 years (petrol en‐
gine)
Interval service (fixed): YES
max. 40,000 km or 2 years (diesel en‐
gine)
QG1 vehicles, export Interval service (flexible): YES
max. 30,000 km or 2 years (petrol en‐
gine)
Interval service (flexible): YES
max. 40,000 km or 2 years (diesel en‐
gine)
All vehicles First inspection service after NO
3 years, then every 2 years
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
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fo
en
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
44 3. Service work
Amarok 2011 ➤
n AG. VolkswMaintenance
agen AG - Edition 10.2012
lkswage does
not
Vo gu
by ara
Amarok
ris
ed 2013► nte
tho eo
Service
au intervals 2013► ra
c
ss
From - to PR No. Service: Indicated on
ce
e
nl
pt
Intervals service interval display
du
an
itte
(includes oil change)
y li
erm
ab
ility
2013► QI1 Oil change service (fixed): YES
ot p
wit
every 5,000 km or 1 year
, is n
h re
QI2 Oil change service (fixed): YES
hole
spec
every 7,500 km or 1 year
es, in part or in w
t to the co
QI3 Oil change service (fixed): YES
every 10,000 km or 1 year
QI4 Oil change service (fixed): YES
rrectness of i
every 15,000 km or 1 year
l purpos
nform
ercia
at
om
io
QI1, QI2, QI3, QI4, QI5, QI7 Interval service (fixed): YES
n
c
in t
r
his
e
engine)
at
do
priv
c
QI1, QI2, QI3, QI4, QI5, QI7 Interval service (fixed): YES
um
for
en
ng
t.
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engine) t. Cop py
rig
gh
QI6 Interval service (flexible): YES
ht
pyri by
Vo
every 30,000 km or 2 years (petrol
co lksw
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cted agen
engine) Prote AG.
Note
3. Service work 45
Amarok 2011 ➤
Maintenance - Edition 10.2012
Amarok ► 2012
Oil change intervals depending on sulphur content in fuel
Fuel quality (EN590) ◀ 500 ppm 500-2,000 ppm 2,000-4,000 ppm ► 4,000 ppm
Change interval ESI 20 tkm/1 year 10 tkm/1 year 7.5 tkm/1 year 5 tkm/1 year
Australia X
Bahamas X
Bahrain X
Bangladesh X
Belgium X
Belize X
AG. Volkswagen AG d
Benin agen oes X
o lksw not
V gu
by
Bermuda ised ara
nte X
or eo
Bhutan aut
h
X ra
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Bolivia X
ce
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un
pt
Bosnia-Herzegovina X
an
d
itte
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erm
Botswana X
ab
ility
ot p
wit
is n
ries
h re
ole,
spec
Brunei X
urposes, in part or in wh
Bulgaria X
t to the co
Burkina Faso X
Burundi rrectne
X
Chile X
s
China X
s o
cial p
Costa Rica X
inform
mer
Denmark X
atio
m
n
c
i
or
Djibouti X
thi
te
sd
va
Dominican Republic X
i
o
pr
cum
r
fo
Dubai X
en
ng
t.
yi Co
op
Ecuador X
C py
t. rig
gh ht
yri
El Salvador X
p by
o Vo
by c lksw
cted
Ivory Coast X
agen
Prote AG.
Eritrea X
Estonia X
Finland X
France X
French Overseas Territo‐ X
ries (not EU)
French Guyana X
Gabon X
Gambia X
Georgia X
Ghana X
Gibraltar X
Greece X
Great Britain and North‐ X
ern Ireland
46 3. Service work
Amarok 2011 ➤
Maintenance - Edition 10.2012
Amarok ► 2012
Oil change intervals depending on sulphur content in fuel
Fuel quality (EN590) ◀ 500 ppm 500-2,000 ppm 2,000-4,000 ppm ► 4,000 ppm
Change interval ESI 20 tkm/1 year 10 tkm/1 year 7.5 tkm/1 year 5 tkm/1 year
Guadeloupe X
Guatemala X
Guinea X
Guinea-Bissau X
Guyana X
Haiti X
Honduras X
Hong Kong X
India X
Indonesia X
Iraq X
Iran X
Ireland X
Iceland X G. Volkswagen
A AG do
agen
Israel Volksw X es n
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by ua
Italy orised
X ran
tee
h
Jamaica aut or
ac X
ss
Japan X
ce
e
nl
pt
du
an
Yemen X
itte
y li
erm
ab
Jordan X
ility
ot p
Cambodia X
wit
, is n
h re
Cameroon X
hole
spec
Canada X
es, in part or in w
t to the co
Cap Verde X
Caribbean driving on the X
rrectness of i
left
Caribbean driving on the X
l purpos
right
Kazakhstan X
nf
ercia
or
Qatar X
m
m
atio
m
Kenya X
o
n in
or c
Kyrgyz Republic X
thi
te
sd
iva
Columbia X
o
r
rp
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Comoros X
f
en
ng
t.
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op
Croatia X C py
t. rig
gh ht
Cuba X
pyri by
Vo
co lksw
by
Kuwait X
cted agen
Prote AG.
Laos X
Lesotho X
Latvia X
Lebanon X
Liberia X
Libya X
Lithuania X
3. Service work 47
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
Amarok 2011 ➤ rised
nte
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Maintenance - Edition 10.2012
aut
h
ra
ss c
ce
e
nl
Amarok ► 2012
pt
du
an
itte
y li
Oil change intervals depending on sulphur content in fuel
erm
ab
ility
Fuel quality (EN590) ◀ 500 ppm 500-2,000 ppm 2,000-4,000 ppm ► 4,000 ppm
ot p
wit
, is n
Change interval ESI 20 tkm/1 year 10 tkm/1 year 7.5 tkm/1 year 5 tkm/1 year
h re
hole
spec
Luxembourg X
es, in part or in w
t to the co
Madagascar X
Malawi X
Malaysia X
rrectness of i
Mali X
l purpos
Malta X
Morocco X
nform
ercia
Martinique X
m
at
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io
Mauritania X
n
c
in t
or
Mauritius X
his
ate
do
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Mayotte X
p
cum
for
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Macedonia X
n
t.
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op
Mexico X
C py
ht. rig
rig ht
by
Moldova X
copy Vo
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cted agen
Mongolia Prote
X
AG.
Montenegro X
Mozambique X
Mozambique X
Myanmar (Burma) X
Namibia X
Nepal X
New Caledonia X
New Zealand X
Nicaragua X
Netherlands X
Dutch Overseas Territo‐ X
ries
Niger X
Nigeria X
North Korea X
Norway X
Oman X
Austria X
Pakistan X
Palestinian Territories X
Panama X
Papua New Guinea X
Paraguay X
Pacific driving on the left X
Pacific driving on the right X
Peru
Philippines X X
Poland X
Portugal X
48 3. Service work
Amarok 2011 ➤
Maintenance - Edition 10.2012
Amarok ► 2012
Oil change intervals depending on sulphur content in fuel
Fuel quality (EN590) ◀ 500 ppm 500-2,000 ppm 2,000-4,000 ppm ► 4,000 ppm
Change interval ESI 20 tkm/1 year 10 tkm/1 year 7.5 tkm/1 year 5 tkm/1 year
Puerto Rico agen
AG. Volkswagen AG d
oes X
olksw not
Republic of Congo d by
V gu
ara X
ise nte
Reunion X uthor eo
ra
a
Rwanda ss c
X
ce
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nl
Romania X
pt
du
an
itte
y li
Russian Federation X
erm
ab
ility
Saint-Barthélemy X
ot p
wit
, is n
Zambia X
h re
hole
spec
Sao Tome and Príncipe X
es, in part or in w
Saudi Arabia X
t to the co
Sweden X
Switzerland X
rrectness of i
Senegal X
l purpos
Serbia X
Seychelles X
nf
ercia
or
Sierra Leone X
m
m
atio
m
Zimbabwe X
o
n in
or c
thi
Singapore X
te
sd
iva
Slovakia X
o
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rp
cu
o
m
f
Slovenia X
en
ng
t.
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op
Somalia X
C py
t. rig
gh ht
yri
Spain X
p by
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by c lksw
cted agen
Sri Lanka and the Mal‐ Prote X
AG.
dives
South Africa X
Sudan X
South Korea X
Surinam X
Swaziland X
Syria X
Tajikistan X
Taiwan X
Tanzania X
Thailand X
Togo X
Trinidad and Tobago X
Chad X
Czech Republic X
Tunisia X
Turkey X
Turkmenistan X
Uganda X
Ukraine X
Hungary X
3. Service work 49
Amarok 2011 ➤
Maintenance - Edition 10.2012
Amarok ► 2012
Oil change intervals depending on sulphur content in fuel
Fuel quality (EN590) ◀ 500 ppm 500-2,000 ppm 2,000-4,000 ppm ► 4,000 ppm
Change interval ESI 20 tkm/1 year 10 tkm/1 year 7.5 tkm/1 year 5 tkm/1 year
Uruguay X
USA-1 federal states X
without CARB require‐
ment
n AG. Volkswagen AG do
USA-2 federal states with olkswage es n
ot g X
CARB requirement byV ua
ed ran
ris
Uzbekistan utho tee
or X
a ac
Venezuela ss X
ce
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nl
pt
du
an
itte
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Vietnam X
erm
ab
ility
Belarus X
ot p
wit
, is n
West Sahara X
h re
hole
spec
Central African Republic X
es, in part or in w
Cyprus X
t to the co
rrectness of i
3.3 Scopes of service
l purpos
at
om
in t
or
do
riv
cum
for
en
ng
♦ Battery: Perform visual check and check magic eye (if fitted) ⇒ page 84
♦ Radio code: Request (customer should be informed of radio code IF DESIRED) ⇒ page 131
Vehicle interior
50 3. Service work
Amarok 2011 ➤
Maintenance - Edition 10.2012
♦ Door handles, door locks, central locking and windows: Check function and ease of
movement agen
AG. Volkswagen AG d
o
ksw es n
Vol ot g
by ua
♦ Front passenger airbags: Check key switch and ed“ON/OFF function”, set switch to “ON” ran ⇒ page 88
oris tee
th or
u
♦ Electric window regulators: Check positioning
ss
a
(open and close functions) ⇒apage
c 102
ce
e
nl
pt
du
♦ Clock: Set to correct time ⇒ page 146
an
itte
y li
erm
ab
♦ Climatronic: Set temperature to 22 ℃ ⇒ page 101
ility
ot p
wit
, is n
h re
♦ Transportation mode: Switch off
hole
spec
es, in part or in w
♦ Radio/radio navigation system: Activate anti-theft coding, store local radio stations to ⇒ page 133
t to the co
station buttons
♦ Radio navigation system: Insert navigation CD/DVD and perform update ⇒ page 134
rrectness of i
♦ Seat protective covers and protective foils: Remove
l purpos
♦ Vehicle interior: Check for cleanliness (front and rear seats, interior trim, carpets/mats,
nf
ercia
windows)
orm
m
atio
m
Vehicle exterior
o
n in
or c
♦ All equipment that has been packed inside the vehicle (mats, wipers, spoilers, roof aerial,
thi
te
sd
a
full sized wheel trims/wheel trims, wheel bolt covers, tyre valve extensions): Install (if
iv
o
r
rp
cu
featured)
o
m
f
en
ng
t.
yi Co
♦ Edge protection on doors (plastic foil): Remove Cop py
t. rig
gh ht
yri by
♦ Vehicle exterior: Check for cleanliness (paintwork, decorative parts, windows, wiper
op Vo
by c lksw
cted
blades, surfaces)
agen
Prote AG.
Tyres
♦ Spare wheel tyre: Check condition and inflation pressure (if fitted) ⇒ page 89
Vehicle, bottom
♦ Vehicle from below (without removing underbody protection): Perform visual check for ⇒ page 146
leaks and damage ⇒ page 110
♦ Engine, CV joint boots/bellows, brake system, steering, axles, gearbox/final drive, ho‐
ses, fluid reservoirs/containers
3. Service work 51
Amarok 2011 ➤
Maintenance - Edition 10.2012
♦ Brake system: Perform visual check for leaks and damage ⇒ page 92
Engine compartment
♦ Engine and components in engine compartment (from above): Perform visual check for ⇒ page 126
leaks and damage
♦ Window wash/wipe system and headlight washer system: Check function and settings; ⇒ page 134
replenish to maximum level
♦ Engine oil level: Check (observe VW engine oil standards if replenishing) ⇒ page 122
Documentation/final checks
♦ Number and function of keys: Check, wipe off grease if necessary
♦ Vehicle data sticker: Stick into service schedule and in vehicle ⇒ page 59
♦ Service schedule: Enter delivery inspection, enter a cross for the 1st service and com‐
plete vehicle data in service schedule, see “Vehicle delivery documentation”
♦ Interval service for vehicles with LongLife service (PR No. QG1) 1)
♦ Oil change service for vehicles with time or distance dependent
AG. Voservice
lkswagen(PR
AG doNo. QG0/
agen
QG2) 1) yV
olksw es n
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b ua
ed ran
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♦ Vehicle literature: Check literature is complete
tho and prepare for handover to customer or
au ac
ss
♦ Reset service interval display ⇒ page 141
ce
e
nl
pt
du
an
itte
y li
ab
ility
ot p
wit
, is n
1) Service identification
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote
52
AG.
3. Service work
Amarok 2011 ➤
Maintenance - Edition 10.2012
Note
1) 2) 3)
y li
erm
ab
ility
Electrics
ot p
wit
is n
X ♦ Front lights - Check function: Side lights, dipped beam, main beam, fog lights, turn signals,
h re
ole,
⇒ page 138
t to the co
X ♦ Rear lights - Check function: brake lights (including 3rd brake light), tail lights, reversing
lights, rear fog light, number plate light, turn signals, hazard warning lights
rrectne
X ♦ Interior, luggage and glove compartment lights, cigarette lighter, sockets, horn and warn‐
ing lamps: Check function
ss o
cial p
⇒ page 84
atio
om
Vehicle exterior
n
c
i
or
n thi
e
sd
iva
o
pr
⇒ page 145
um
r
fo
en
ng
X ♦ Windscreen wash and wipe system: Check function, spray jet settings and for damage,
t.
yi Co
op
adjust if necessary
C py
t. rig
gh ht
yri by
⇒ page 134
cop Vo
by lksw
cted agen
X ♦ Wiper blades: Check for damage and park position, adjust as necessary
Prote AG.
⇒ page 137
X ♦ Paint: Perform visual check for damage and corrosion, interior and exterior when doors
and bonnet/rear lid/flaps are open
⇒ page 145
X • Bonnet catch: Clean, ensure attachment is secure and lubricate
⇒ page 6
X X • Windscreen: Perform visual check for damage
Tyres
3. Service work 53
Amarok 2011 ➤
Maintenance - Edition 10.2012
X ♦ Tread depth, condition, wear pattern, age, inflation pressure (including spare tyre):
Check, rectify as necessary
⇒ page 89
Vehicle from below
X ♦ Engine and components in engine compartment (from below), gearbox, final drive, rear
axle and protective bellows: Perform visual check for leaks and damage
♦ If fluid loss is greater than can be expected through normal use, determine cause and
rectify using a special order
AG. Volkswagen A
⇒ page 126 wage
n G do
es n
Volks ot g
y
X ♦ Underbody:
ise
d Visual check for damage to underbody
b ua
ran protection and underbody trim/panels
r tee
ho
⇒ page au146
t or
ac
ss
X ♦ Exhaust system: Visual check for leaks, security and damage
ce
e
nl
pt
du
an
itte
y li
X ♦ Check track rod ends:
erm
ab
ility
ot p
wit
, is n
h re
⇒ page 144
hole
spec
X ♦ CV joints, axial bearings, coupling rod bearings and anti-roll bar rubber bushes: Visual
es, in part or in w
t to the co
⇒ page 79
X ♦ Brake system: Perform visual check for leaks and damage
rrectness of i
⇒ page 92
l purpos
X X ♦ Thickness of brake pads and condition of front brake discs and rear drum brake linings:
check
nform
ercia
⇒ page 93
m
at
om
io
Engine compartment
n
c
in t
or
X ♦ Engine oil level: Check, observe oil specification when topping up!
his
ate
do
riv
⇒ page 122
p
cum
for
en
g
X ♦ Engine and components in engine compartment (from above): Perform visual check for
n
t.
yi Co
op
leaks and damage C py
t. rig
gh ht
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⇒ page 126
p by
co Vo
by lksw
cted
X X ♦ Engine oil: Change and renew oil filter, ensure level is at maximum after filling system
agen
Prote AG.
and replenish if necessary
• Note VW engine oil standards
⇒ page 122
X ♦ Brake fluid: Change (after 3 years from initial registration and then every 2 years)
⇒ page 95
X ♦ Brake fluid level (depending on lining wear): Check (observe specification )
⇒ page 100
X ♦ Brake system and shock absorbers: Perform visual check for leaks and damage
⇒ page 95
X ♦ Power assisted steering: Check fluid level
⇒ page 144
X ♦ Air filter with saturation indicator in dash panel insert: Check
• In countries with high levels of dust, a new dust and pollen filter must be fitted as a sep‐
arate job order
⇒ page 118
54 3. Service work
Amarok 2011 ➤
Maintenance - Edition 10.2012
X ♦ Cooling system: Check frost protection and coolant level, replenish if necessary
• Specified antifreeze value: “-25 °C” In countries with an arctic climate “-35 °C”
⇒ page 115
Final checks
X ♦ Headlight adjustment: Check, if necessary adjust
X X X ♦ “Your next service” sticker: Enter next due date 1) and attach service sticker to driver side
door pillar (B-pillar)
X ♦ Breakdown set (if fitted): Check (renew tyre inflation bottle with sealant if use-by date has
expired)
pt
du
an
y li
erm
work
ab
ility
ot p
h re
spec
es, in part or in w
t to the co
♦ Dust and pollen filter (cabin filter): Clean housing and renew filter Every 30,000 km ⇒ page 110
element
rrectness of i
♦ Air filter: Clean housing and renew filter element Every 30,000 km ⇒ page 118
l purpos
♦ Fuel filter: Renew – if vehicle runs on diesel fuel every 10,000 km or ⇒ page 113
m
at
om
6 months
ion
c
in t
r
his
te
6 months
a
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
Brazil market from model year 2011 gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
3. Service work 55
Amarok 2011 ➤
Maintenance - Edition 10.2012
♦ Air filter: Clean housing and renew filter element Every 90,000 km ⇒ page 118
or
– Reset programmed values in engine control unit -J623- 6 years
♦ Spark plugs: Renew Every 90,000 km ⇒ page 149
AG. Volkswagen AGor
swagen does
yV
olk 6 yearsnot gua
edb ra
♦ Fuel filter: Renew – if vehicle runs on diesel hfuel
or
is Every 60,000 km nte⇒ e page 113 t or
au ac
ss
♦ Camshaft drive toothed belt: Check every 10,000 km ⇒ page 148
ce
le
or
un
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an
d
6 months
itte
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spec
urposes, in part or in wh
t to the co
Additional work Interval Description of
work
rrectne
♦ Spark plugs: Renew Every 20,000 km ⇒ page 149
ss o
cial p
f inform
3.3.4 Time and distance dependent additional
mer
atio
work
om
n
c
i
or
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♦ Depending on conditions under which the vehicle is used and
thi
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addition to the inspection service or oil change service/interval
um
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separately and are marked as extra work. t. Cop py
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Measure: Interval
p by
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• Thickness of brake pads and condition of front Prote
Recommendation: 1)
AG.
brake discs and rear drum brake linings: check
56 3. Service work
Amarok 2011 ➤
Maintenance - Edition 10.2012
Measure: Interval
♦ Dust and pollen filter (cabin filter): Clean housing Every 60,000 km
and renew filter element
⇒ page 110
♦ Spark plugs: Renew wage
n AG. Volkswagen AG do
es n
lks ot g
Vo
⇒ page 149 d by ua
ran
ir se tee
♦ Air filter: Clean housing and renew filter elementutho
or
(reset learnt values of engine control unit -J623-
ss
a
) ac
ce
le
un
♦ Valid in “dusty” regions
pt
an
d
itte
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• In countries with high levels of dust, a new dust and
erm
ab
pollen filter must be fitted as a separate job order
ility
ot p
wit
is n
⇒ page 118
h re
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spec
urposes, in part or in wh
t to the co
♦ Conforming to “DIN EN 590”
♦
rrectne
⇒ page 113
♦ Air filter: Clean housing and renew filter element Every 120,000 km
s
(reset learnt values of engine control unit -J623- )
s o
cial p
f in
⇒ page 118
form
mer
atio
m
n
c
i
or
n thi
• Valid in “dusty” regions, diesel engines
te
sd
iva
o
r
⇒ page 148
p
cum
r
fo
en
ng
3. Service work 57
Amarok 2011 ➤
Maintenance - Edition 10.2012
Measure: Interval
♦ Camshaft drive toothed belt: Check Every 2 years
• Valid in “dusty” regions, diesel engines
⇒ page 148
♦ Dust and pollen filter (cabin filter): Clean housing
and renew filter element
⇒ page 110
♦ Air filter: Clean housing and renew filter element Every 3 years
(reset learnt values of engine control unit -J623- )
♦ Valid in “dusty” regions
• In countries with high levels of dust, a new dust and
pollen filter must be fitted as a separate job order
♦ Emissions test: Perform (every 12 months in Ger‐ 3 years after initial registration and then every 2 years
many for commercial passenger transport, e.g.
taxis)
. Volkswage
⇒ page 152 wage
n AG n AG d
oes
olks no
♦ Fuel filter: Renewby – if vehicle runs on diesel fuel t gua
V
Every 4 years
ed ra nte
ris
• That does ho eo
aut not conform with standard “DIN EN 590” ra
ss c
⇒ page 113
ce
le
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an
d
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ab
⇒ page 149
pe
ility
ot
wit
♦ Air filter: Clean housing and renew filter element Every 6 years
, is n
h re
spec
⇒ page 118
es, in part or in w
t to the co
⇒ page 113
l purpos
a
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ti
thi
latest.
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Prote AG.
58 3. Service work
Amarok 2011 ➤
Maintenance - Edition 10.2012
4 General
♦ Sticker ⇒ page 62
♦ Entries in service schedule ⇒ page 63
♦ Severe conditions ⇒ page 60
♦ Vehicle identification number (chassis number) ⇒ page 59
♦ Vehicle data sticker ⇒ page 59
♦ Engine code and engine number ⇒ page 60
♦ Countries with high levels of dust ⇒ page 60
pt
du
an
itte
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ab
wit
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The vehicle data sticker -arrow- is attached to the left A-pillar low‐
h re
hole
This vehicle data sticker is also found in the service schedule for
t to the co
the customer.
On the left side of left-hand drives, on the right side of right-hand
rrectness of i
drives.
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at
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ion
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ate
do
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for
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Cop py
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4. General 59
Amarok 2011 ➤
Maintenance - Edition 10.2012
AG. Volkswagen AG d
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V gu
by
4.3 Severe operating conditionsorised ara
nte
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If the vehicle is used under severess operating conditions some jobs
a c
will have to be performed before the next service due or at shorter
ce
e
nl
pt
service intervals.
du
an
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ab
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• High percentage of cold starts
hole
spec
es, in part or in w
t to the co
a long period
• Frequent long periods with the engine idling (e.g. taxi)
rrectness of i
• Vehicle is often driven at full throttle with high payload or whilst
l purpos
towing a trailer
• Using diesel with elevated sulphur content
nform
ercia
at
om
i
4.4 Engine code and engine number
on
c
in t
or
his
e
do
priv
cum
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♦ On vehicle data sticker on left A-pillar lower trim panel in the Cop py
footwell ⇒ page 59 .
t. rig
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♦ On vehicle data sticker in service schedule for the customer. by c lksw
cted agen
Prote AG.
60 4. General
n AG. Volkswagen AG do Amarok 2011 ➤
lkswage es n
d byV
o ot g
ua Maintenance - Edition 10.2012
ran
ir se tee
tho
or
Country au Dusty country ac
ss
ce
le
Belize X
un
pt
an
Benin d X
itte
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rm
ab
Bhutan X
pe
ility
ot
wit
Bolivia X
, is n
h re
hole
Botswana X
spec
es, in part or in w
Brazil X
t to the co
China X
Guinea-Bissau X
rrectness of i
Guyana X
l purpos
India X
Israel X
nform
ercia
Yemen X
m
a
Jordan X
com
tion in
Cambodia X
r
te o
thi
s
iva
Cameroon X
do
r
rp
cum
Kazakhstan X
fo
en
ng
t.
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Canada X
Co
Cop py
t. rig
Qatar X
gh ht
pyri by
Vo
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by
Kenya Prote
cted X AG.
agen
Kuwait X
Laos X
Lesotho X
Lebanon X
Liberia X
Libya X
Madagascar X
Malawi X
Mali X
Singapore X
Somalia X
Sri Lanka/Maledives, X
South Africa, Sudan
Surinam X
Swaziland X
Tanzania X
Thailand X
Togo X
Chad X
Tunisia X
Turkey X
Turkmenistan X
USA-2 X
Uzbekistan X
Venezuela X
United Arab Emirates X
Vietnam X
Belarus X
4. General 61
Amarok 2011 ➤
Maintenance - Edition 10.2012
4.6 Sticker
♦ Attaching service sticker “Your next service dates”
⇒ page 62 .
♦ Attaching “vehicle data sticker” into customer service schedule
and in vehicle ⇒ page 62
n AG. Volkswagen AG do
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– Apply service sticker on driver side door pillar (B-pillar).
ss
ce
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un
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an
d
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ab
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wit
is n
h re
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spec
urposes, in part or in wh
t to the co
rrectnes
f i
atio
n
c
i
or
schedule.
t
sd
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cum
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t.
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Cop py
t. rig
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co lksw
by
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Prote AG.
62 4. General
Amarok 2011 ➤
Maintenance - Edition 10.2012
AG. Volkswagen AG d
agen oes
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V gu
d by ara
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or eo
h
aut ra
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ce
le
un
pt
an
d
itte
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ab
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wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
turer,
♦ the time period for the new replacement interval starts when
the replacement is carried out.
rrectne
♦ Therefore it is very important, every time a component is
changed, to document this in the service schedule. This also ss o
applies to components which were changed before the regular
cial p
f i
change interval.
nform
mer
⇒ page 145 .
o
n
c
i
or
n thi
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sd
iva
Note
pr
cum
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fo
en
ng
t.
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♦ When using genuine parts kits, it must be taken into account
Co
op py
whether it is technically necessary to change all the compo‐
t. C rig
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nents included in the genuine parts kits. p by
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♦ If more components are renewed than is technically necessa‐ Prote AG.
ry, inform the customer before repair!
4. General 63
AG. Volkswagen AG d
agen oes
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Amarok 2011 ➤ by Vol
gu
ara
d
Maintenance - Edition 10.2012 orise nte
eo
th
au ra
ss c
ce
5 Descriptions of work
le
un
pt
an
d
itte
y li
♦ Swivel joints: Visual check ⇒ page 79
rm
ab
pe
ility
♦ Four-wheel drive: Insert fuse ⇒ page 107
ot
wit
, is n
h re
♦ Lifting the vehicle ⇒ page 65
hole
spec
es, in part or in w
♦ Reading ash mass (saturation level) of diesel particulate filter
t to the co
⇒ page 80
♦ Battery: Check battery terminal clamps for secure seating
⇒ page 81 .
rrectness of i
♦ Battery: Check magic eye ⇒ page 84
l purpos
nform
ercia
⇒ page 84
a
com
tion in
♦ Front passenger front airbag: Check key switch and “On/Off
r
te o
thi
function” ⇒ page 88 .
s
iva
do
r
rp
c
♦ Checking tyres: Condition, wear pattern, tyre pressure, tread
um
fo
depth ⇒ page 89
en
ng
t.
yi Co
op
♦ Brake system: Perform visual check for leaks and damage
C py
t. rig
gh
⇒ page 92
ht
pyri by
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♦ Brake fluid level: Check ⇒ page 100
agen
Prote AG.
64 5. Descriptions of work
Amarok 2011 ➤
Maintenance - Edition 10.2012
ce
e
nl
pt
du
an
♦ Radio / radio navigation system: Enter anti-theft coding PIN
itte
y li
erm
⇒ page 133 .
ab
ility
ot p
wit
, is n
h re
hole
spec
♦ Doors: Grease door arrester ⇒ page 145
es, in part or in w
t to the co
♦ Windscreen wash/wipe system and headlight washer system:
Check function and settings ⇒ page 134
rrectness of i
♦ Windscreen wiper blades: Check park position ⇒ page 137 .
l purpos
nf
ercia
orm
m
atio
om
n in
c
thi
te
sd
a
o
r
rp
cu
⇒ page 144
o
m
f
en
ng
t.
yi
♦ Dust and pollen filter: Clean housing and renew filter element
Co
op py
⇒ page 110
t. C rig
gh ht
pyri by
Vo
♦ Clock: Set to correct time ⇒ page 146
o
by c lksw
cted agen
Prote AG.
♦ Underbody protection: Perform visual check for damage
⇒ page 146
♦ Removing and installing skid plate ⇒ page 150
♦ Camshaft drive toothed belt: Check condition ⇒ page 148
♦ Camshaft drive toothed belt: Renew ⇒ page 148
♦ Spark plugs: Renew ⇒ page 149
5. Descriptions of work 65
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
r
Amarok 2011 ➤ ut
ho eo
ra
a
Maintenance - Edition 10.2012 ss c
ce
e
nl
pt
du
an
5.1.1 Safety notes
itte
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ab
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WARNING
wit
, is n
h re
hole
spec
♦ Before driving onto a lifting platform, ensure that there is
es, in part or in w
sufficient clearance between low-lying vehicle compo‐
t to the co
nents and lifting platform.
♦ Before driving a vehicle onto a lifting platform it must be
rrectness of i
ensured that the vehicle weight does not exceed the per‐
missible lifting capacity of the platform. l purpos
♦ Vehicle may be lifted only at points indicated in figure to
avoid damaging vehicle underbody or tipping vehicle.
nf
ercia
or
♦ Never start engine when vehicle is raised and do not en‐
m
m
atio
gage a gear in gearbox even if only one driven wheel is
om
n in
touching floor. Disregarding these warnings risks the dan‐
or c
ger of an accident!
thi
te
sd
iva
o
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cu
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m
decide whether to strap the vehicle down on the lifting
f
en
ng
t.
yi
platform or not.
Co
Cop py
t. rig
♦ If the vehicle is not strapped down, there is a great danger
gh ht
pyri by
that the vehicle will slip off the lifting platform.
o Vo
by c lksw
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Prote AG.
♦ Laden vehicles are only allowed to be raised using wheel
lifts as main support. If wheels need to be removed, it is
also permissible to lift laden vehicles by means of pris‐
matic supports under the rear axle tube. If this is not
possible because work is to be performed on rear axle, the
load must be removed from the vehicle.
♦ If vehicle is jacked up with a workshop jack in order to work
underneath it, it must be securely supported using suitable
stands.
66 5. Descriptions of work
Amarok 2011 ➤
Maintenance - Edition 10.2012
Note
♦ Raising vehicle with wheel lifts should mainly be done for all
assembly work on vehicle.
♦ Only use support points listed in document when assembly
work is performed on running gear or on axles.
♦ Vehicle must under no circumstances be raised on sills, oth‐
erwise its body will be seriously damaged.
G. Volkswagen AG d
♦ When work is to be done on the running gear (front axlelkand
swa
gen A oes
rear axle), raising the vehicle with jacks under the rear y Vaxle
o not
gu
db ara
should only be done as an alternative to the main rismethod of
e nte
supporting the vehicle! aut
ho eo
ra
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♦ If work is to be done on the running gear, e.g. removal of front
ce
e
axle and rear axle, another way of raising the vehicle is to use nl
pt
du
an
jacks in front of the rear axle tube.
itte
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ab
♦ The vehicle may only be lifted at points indicated in order to
ility
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wit
, is n
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♦ Vehicle must under no circumstances be raised on sills, oth‐
hole
spec
erwise its body will be seriously damaged.
es, in part or in w
t to the co
♦ To avoid damage, make sure that no electrical cables, brake
lines or fuel lines become trapped.
rrectness of i
♦ Laden vehicles must be unloaded before being raised.
l purpos
nform
mercia
at
om
i
are replaced by 4 wheel lift supports -1-.
on
c
in t
or
his
ate
do
riv
cum
for
en
ng
t.
yi
actly in wheel lifts.
Co
Cop py
ht. rig
rig ht
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by lksw
cted agen
Prote AG.
5. Descriptions of work 67
Amarok 2011 ➤
Maintenance - Edition 10.2012
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
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an
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ab
ility
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wit
is n
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ole,
spec
urposes, in part or in wh
t to the co
– Vehicle can now be raised and lowered to required working
height.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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o
pr
cum
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t.
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Cop py
t. rig
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by c lksw
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Prote AG.
68 5. Descriptions of work
Amarok 2011 ➤
Maintenance - Edition 10.2012
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
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ce
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nl
pt
du
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itte
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ab
ility
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wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Raising vehicle under rear axle tube
Special tools and workshop equipment required
♦ Prismatic support with minimum opening angle 120°. Note that rrectness of i
the versions differ from one lifting platform manufacturer to
l purpos
another.
nf
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m
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om
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or c
thi
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sd
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rig ht
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by lksw
cted
Perform the following jobs:
agen
Prote AG.
5. Descriptions of work 69
Amarok 2011 ➤
Maintenance - Edition 10.2012
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
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tho
u or
a ac
ss
ce
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nl
pt
du
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itte
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erm
ab
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wit
, is n
h re
hole
spec
height.
t to the co
rrectness of i
l purpos
nf
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orm
m
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om
n in
or c
thi
te
sd
iva
o
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cu
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
70 5. Descriptions of work
Amarok 2011 ➤
Maintenance - Edition 10.2012
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
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un
pt
an
d
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ab
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wit
is n
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spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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o
pr
cum
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fo
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ng
t.
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Cop py
t. rig
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Raising vehicle before rear axle tube
p by
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by lksw
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Perform the following jobs:
Prote AG.
5. Descriptions of work 71
Amarok 2011 ➤
Maintenance - Edition 10.2012
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
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un
pt
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d
itte
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ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectne
– Vehicle can now be raised and lowered to required working
height.
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
72 5. Descriptions of work
Amarok 2011 ➤
Maintenance - Edition 10.2012
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
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nl
pt
du
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itte
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ab
ility
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wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
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orm
m
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om
n in
or c
thi
te
sd
iva
o
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cu
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f
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ng
t.
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Cop py
ht. rig
rig ht
py by
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by lksw
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Prote AG.
Note
♦ If work is to be done on the running gear, e.g. removal of front axle and rear axle, another way of raising the
vehicle is to use jacks in front of the rear axle tube.
♦ The vehicle may only be lifted at points indicated in order to avoid damaging vehicle and to prevent vehicle
from tipping.
♦ Laden vehicles must be unloaded before being raised.
♦ Vehicle must under no circumstances be raised on sills or front leaf spring supports, otherwise it will slip off
and its body could be seriously damaged.
♦ To avoid damage, make sure that no electrical cables, brake lines or fuel lines become trapped.
5. Descriptions of work 73
Amarok 2011 ➤
Maintenance - Edition 10.2012
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
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nl
pt
du
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ab
ility
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wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
r
his
te
height.
a
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
74 5. Descriptions of work
Amarok 2011 ➤
Maintenance - Edition 10.2012
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
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Prote AG.
5. Descriptions of work 75
Amarok 2011 ➤
Maintenance - Edition 10.2012
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
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aut ra
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nl
pt
du
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ab
ility
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wit
, is n
h re
spec
height.
es, in part or in w
t to the co
rrectness of i
l purpos
nf
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orm
m
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om
n in
or c
thi
te
sd
iva
o
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t.
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Cop py
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pyri by
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Prote AG.
76 5. Descriptions of work
Amarok 2011 ➤
Maintenance - Edition 10.2012
AG. Volkswagen AG d
agen oes
olksw not
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aut ra
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ab
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spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f i
5.1.4 Additional support of vehicle
nform
mer
atio
om
n
c
Note i
or
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t.
support arms of lifting platform with tensioning straps -
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♦ To avoid damage, make sure that no electrical cables, brake
co Vo
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lines or fuel lines become trapped.
agen
Prote AG.
5. Descriptions of work 77
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Amarok 2011V➤ olks
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Maintenance
ise
d b - Edition 10.2012 ara
nte
r
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aut ra
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un
pt
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d
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rm
ab
pe
ility
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wit
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
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r
rp
cum
fo
en
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t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.
78 5. Descriptions of work
Amarok 2011 ➤
Maintenance - Edition 10.2012
AG. Volkswagen AG d
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5.2 Swivel joints: Visual check ss a ra
c
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erm
ab
ility
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wit
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h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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pr
cum
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t.
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5. Descriptions of work
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Amarok 2011 ➤ tho tee
or
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Maintenance - Edition 10.2012 ss
a ac
ce
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nl
pt
du
– Check boots -arrow- of lower swivel joints for leaks and dam‐
an
itte
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age.
erm
ab
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nf
ercia
– Check boots -arrow- of upper swivel joints for leaks and dam‐
orm
age.
m
atio
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n in
or c
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t.
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Cop py
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pyri by
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Prote AG.
Note
80 5. Descriptions of work
Amarok 2011 ➤
Maintenance - Edition 10.2012
aged.
un
pt
an
d
itte
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ab
pe
ility
wit
, is n
h re
t to the co
nform
mercia
a
com
tion in
r
te o
thi
s
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t.
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5.4.1 Battery: Check battery terminal clamps
co Vo
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Prote
for secure seating
AG.
Note
5. Descriptions of work 81
Amarok 2011 ➤
Maintenance - Edition 10.2012
Note
WARNING
If the battery terminal clamp is not seated securely on the pos‐ agen
AG. Volkswagen AG d
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itive terminal, first disconnect battery terminal clamp from bat‐ olksw not
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If the battery terminal clamp is not seated securely on positive
ce
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terminal:
an
itte
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ab
Perform the following jobs:
ility
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terminal first.
hole
spec
– Open battery positive terminal cover.
es, in part or in w
t to the co
– Tighten battery terminal clamp -2- on battery positive terminal
to specified torque ⇒ page 83
rrectness of i
– Close battery positive terminal cover.
l purpos
nform
ercia
at
securely:
om
ion
c
in t
Perform the following jobs:
or
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ate
do
priv
cum
for
en
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t.
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op py
– Tighten battery terminal clamp -1- on battery positive terminal t. C rig
gh ht
to specified torque ⇒ page 83 . yri
p by
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82 5. Descriptions of work
Amarok 2011 ➤
n AG. Volkswagen AG do Maintenance - Edition 10.2012
lkswage es n
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5.4.2 Battery terminal connections tho
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or
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Caution
nl
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To prevent damage to the battery terminal clamps and the bat‐
erm
ab
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tery terminals, observe the following:
ot p
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♦ The battery terminal clamps must only be connected by
h re
hole
spec
es, in part or in w
t to the co
♦ Fit battery terminal clamps in such a way that the battery
terminal is flush with the clamp or protrudes from it.
rrectness of i
♦ When connecting the battery, always follow the procedure
l purpos
nf
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m
atio
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n in
c
thi
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⇒ page 83 .
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t.
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t. rig
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pyri by
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Prote AG.
Caution
5. Descriptions of work 83
Amarok 2011 ➤
Maintenance - Edition 10.2012
WARNING
Risk of injury! Take note of the warnings and comply with the
safety regulations ⇒ Electrical system; Rep. gr. 27 ; Warnings
and safety regulations .
olkswagen AG
en AG. V
The magic eye provides informationolconcerning
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ag the electrolyte
does
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level of battery. ed
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or
– Lightly tap the magic eye
au with the handle of a screwdriver.
th eo
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Note
an
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ab
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The air bubbles in the battery rise. In this way, falsification of the
ot p
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spec
t to the co
black
Electrolyte level indication: col‐ Electrolyte level too low The
l purpos
WARNING
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out, there is a danger of explosion. . Cop py
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These batteries must be replaced.
rig by
copy Vo
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Prote AG.
84 5. Descriptions of work
Amarok 2011 ➤
Maintenance - Edition 10.2012
ce
le
un
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d
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Note
rm
ab
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ility
ot
wit
♦ The battery terminal clamps must only be connected by hand
, is n
h re
without using force, to ensure the battery housing is not dam‐
hole
spec
aged.
es, in part or in w
t to the co
♦ Battery terminals must not be greased.
♦ Disconnecting the battery earth cable ensures safe working
on the electrical system.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
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cum
fo
en
ng
t.
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Cop py
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pyri by
Vo
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by c lksw
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Prote AG.
5. Descriptions of work 85
AG. Volkswagen AG d
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olksw not
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d b ara
ise nte
Amarok 2011 ➤ thor eo
u ra
Maintenance - Edition 10.2012 ss a c
ce
le
un
pt
– Separate connector -2- of electrical wiring harness for battery
an
d
itte
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cut-off relay from brake fluid reservoir.
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
a
com
tion in
r
te o
thi
s
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do
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cum
fo
en
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t.
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Cop py
t. rig
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pyri by
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Prote AG.
– Unscrew securing bolt (10 mm) -1- of battery cut-off relay from
jump start point for battery positive terminal and remove.
– Loosen hexagon flange nut (10 mm) -1- from battery cut-off
relay and remove cable to main fuse box -2- from connection.
Procedure for RHD vehicles
On RHD vehicles an additional adapter cable is installed to extend
the electrical wiring harness of the battery cut-off relay to connect
the brake fluid reservoir on the right in engine compartment.
Perform the following jobs:
– Open cable tie -1- on centre of bulkhead and remove electrical
wiring harness of battery cut-off relay -2- with adapter cable
-3- from cable tie.
86 5. Descriptions of work
Amarok 2011 ➤
Maintenance - Edition 10.2012
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
– Unscrew jump start point (17 mm) -1- from battery
ss positive c
terminal and remove.
ce
e
nl
pt
du
an
– Route cable to main fuse box -2- to battery positive terminal. itte
y li
erm
ab
– Place the cable in the envisaged position -arrow- in the termi‐
ility
ot p
wit
, is n
h re
hole
– Now secure cable to main fuse box -2- with jump start point
spec
-1- to battery positive terminal.
es, in part or in w
t to the co
rrectness of i
l purpos
Specified torque: 8 ± 1 Nm
nf
ercia
orm
m
atio
om
n in
or c
thi
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t.
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Cop py
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pyri by
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Prote AG.
– Remove red terminal cap -1- from ashtray and insert it into
thread of jump start point -2-.
– Reconnect battery terminal clamp to battery negative terminal.
– Tighten securing bolt of terminal clamp to specified torque
⇒ page 83 .
– Install battery cover.
Note
5. Descriptions of work 87
Amarok 2011 ➤
Maintenance - Edition 10.2012
Note
If the airbag is deactivated, the front airbag, side airbag and cur‐
tain airbag are deactivated on the front passenger side. All other
airbags in the vehicle remain functional.
WARNING
Note
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.
88 5. Descriptions of work
Amarok 2011 ➤
Maintenance - Edition 10.2012
n AG. Volkswagen AG do
wage
5.8 Checking tyres: Condition, wear pattern, lks es n
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tyre pressure, tread depth
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Note
pt
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ab
♦ The following descriptions of work also apply to the spare
ility
ot p
wheel, if a spare wheel with standard tyres is fitted.
wit
is n
h re
♦ For safety reasons, only tyres of same type and tread pattern ole,
spec
should be fitted on a vehicle!
urposes, in part or in wh
t to the co
♦ Check tyre age ⇒ page 89
♦ Tyre pressures (including spare wheel): Check, correct if nec‐
rrectne
essary ⇒ page 91
♦ Checking wear pattern ⇒ page 90
ss o
cial p
f
♦ Tyre tread depth (including spare wheel): Check and enter
inform
⇒ page 90
mer
atio
♦ Check condition ⇒ page 89
om
n
c
i
or
n
5.8.1 Check tyre age
thi
te
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ng
Note
t.
yi Co
Cop py
t. rig
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We recommend that summer or winter tyres older than 6 years
ht
pyri by
Vo
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should be taken out of service.
c by lksw
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Prote AG.
Note
The first two digits are for the calendar week (KW); shown as “02”
in this example.
The last two digits indicate the year of manufacture; shown as
“04” in this example.
In this case, therefore, “0204” means that the tyre was produced
in the second week of 2004.
5. Descriptions of work 89
Amarok 2011 ➤
Maintenance - Edition 10.2012
Note
G. Volkswagen
If damage is determined, always check to
lkssee
wageif a new tyre should
nA AG do
es n
be fitted. db
yV
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ua
r e an
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tho or
Tests at interval service au ac
ss
ce
e
pt
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an
itte
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ab
ility
♦ »Tyre treads«
ot p
wit
, is n
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hole
spec
– Remove foreign bodies from tyres such as nails and glass
es, in part or in w
splinters if necessary.
t to the co
– In addition, check the tyres for:
rrectness of i
♦ »Cupping«
l purpos
nform
ercia
♦ »Cuts«
m
at
om
i
♦ »Punctures«
on
c
in t
or
his
ate
do
priv
c
1.)
Tyres that are more than 6 years old should be renewed (rec‐
um
for
en
g
ommendation to customer)
n
t.
yi Co
Cop py
t. rig
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yri by
Note cop Vo
by lksw
cted agen
Prote AG.
The customer must be informed of any faults found.
WARNING
90 5. Descriptions of work
Amarok 2011 ➤
Maintenance - Edition 10.2012
Note
n AG. Volkswagen AG do
wage es n
Note yV
olks ot g
ua
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ir se tee
♦ “Checking tyre inflation pressure” u also applies to the spare
tho
or
a ac
wheel, if a spare wheel with standard
ss tyres is fitted.
ce
le
un
ab
pe
♦ Winter tyres and summer tyres may be used with the same
ility
ot
h re
hole
t to the co
♦ Tyre pressures apply for all tyre sizes fitted in the factory.
l purpos
tion in
♦ Q: up to 160 km/h
r
te o
thi
s
iva
♦ R: up to 170 km/h
do
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rp
cum
fo
♦ S: up to 180 km/h
en
ng
t.
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op
♦ T: up to 190 km/h C py
t. rig
gh ht
yri by
♦ H: up to 210 km/h cop Vo
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cted agen
Prote AG.
5. Descriptions of work 91
Amarok 2011 ➤
Maintenance - Edition 10.2012
♦ V: up to 240 km/h
Tyre pressure table:
Applies to all factory-fitted tyre sizes.
Permitted axle load Type of tyre Half payload Full payload
Full load: FA / RA
(kg)
front rear front rear
1370 / 1860 ♦ 205 R16 C 110/108 T 2.5 2.5 2.8 4.5
pt
an
d
itte
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ab
pe
ility
ot
The spare wheel should have the highest tyre pressure deter‐
wit
, is n
spec
es, in part or in w
t to the co
♦ Brake servo,
nform
ercia
♦ Brake calipers,
com
tion in
r
thi
s
iva
do
cum
fo
– Make sure that brake hoses are not twisted ⇒ Brake hydraulic
en
ng
t.
yi Co
system, regulator, booster; Rep. gr. 47 . . Cop py
rig
ht ht
– In addition, make sure that brake hoses do not contact other
rig by
opy Vo
components across entire steering range.
by c lksw
cted agen
Prote AG.
– Check brake hoses for porosity or brittleness.
– Check brake hoses and lines for chafing.
– Check brake connections and fastenings for correct seating,
leaks and corrosion.
92 5. Descriptions of work
Amarok 2011 ➤
Maintenance - Edition 10.2012
WARNING
ce
le
un
pt
Rear drum brake pads: Check thickness ⇒ page 94
an
d
itte
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erm
ab
Condition of brake discs: Check ⇒ page 94
ility
ot p
wit
Special tools and workshop equipment required
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
en
ng
t.
♦ Fluorescent lamp, 13 watts -VAS 6485-
yi Co
Cop py
t. rig
The adapter for loosening and tightening anti-theft wheel bolts is
gh ht
pyri by
in the vehicle tool kit ⇒ page 130
co Vo
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cted agen
Prote AG.
Note
5. Descriptions of work 93
Amarok 2011 ➤
Maintenance - Edition 10.2012
WARNING
The brake pads have reached their wear limit at a brake pad
thickness of 2 mm (without backplate) and must be renewed
(repair measure). Inform customer!
Note
♦ When replacing disc brake pads, always check brake discs for
wear! Checking and if necessary replacing the brake discs is
a repair measure.
♦ In the case of defective links, please select the described
working procedure manually in the relevant information mate‐
rial.
pt
an
d
itte
ab
wit
is n
h re
ole,
Note
spec
urposes, in part or in wh
t to the co
ness
s o
cial p
f in
atio
n
c
n thi
e
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
94 5. Descriptions of work
n AG. Volkswagen AG do
lkswage es n
o ot g
byV Amarok 2011 ua ➤
d ran
ir se
tho Maintenance - Edition 10.2012 tee
or
au ac
ss
Wear limit: 1.5 mm (lining thickness only).
ce
le
un
pt
an
d
itte
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rm
WARNING
ab
pe
ility
ot
wit
, is n
The brake pads have reached their wear limit at a brake pad
h re
thickness of 2 mm (without backplate) and must be renewed
hole
spec
(repair measure). Inform customer!
es, in part or in w
t to the co
rrectness of i
Note
l purpos
♦ Check linings for brake fluid or grease contamination.
♦ When replacing drum brake linings, always check brake discs
nform
ercia
for wear! Checking and if necessary replacing the brake discs
m
is a repair measure.
a
com
tion in
♦ In the case of defective links, please select the described
r
te o
thi
working procedure manually in the relevant information mate‐
s
iva
do
rial.
r
rp
cum
fo
en
ng
t.
yi
Check brake disc for wear.
Co
Cop py
t. rig
gh
Working procedure; Running gear ► Brake system ► ⇒ Rep. gr.
ht
pyri by
Vo
46 Brake mechanism ► Repairing rear wheel brake.
co lksw
by
cted agen
Prote AG.
WARNING
5. Descriptions of work 95
Amarok 2011 ➤
Maintenance - Edition 10.2012
agen
AG. Volkswagen AG d
o
w es n
olks ot g
byV ua
ed ran
ris tee
WARNING utho or
a ac
ss
♦ Brake fluid must under no circumstances come into con‐
ce
le
un
pt
tact with fluids containing mineral oils (oil, petrol, cleaning
an
d
itte
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solutions). Mineral oils will damage seals and sleeves of
erm
ab
brake system.
ility
ot p
wit
♦ Brake fluid is poisonous. In addition, due to its corrosive
is n
h re
nature, it must not come into contact with paint.
ole,
spec
urposes, in part or in wh
t to the co
surrounding air and therefore must always be stored in air-
tight containers.
♦ Wash away spilt brake fluid using plenty of water.
rrectne
♦ Do not reuse extracted (used) brake fluid!
ss
♦ Observe disposal regulations!
o
cial p
f inform
mer
atio
Special tools and workshop equipment required
om
n
c
i
or
n
♦ Brake filling and bleeding equipment -VAS 5234-
thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
96 5. Descriptions of work
Amarok 2011 ➤
Maintenance - Edition 10.2012
Note
olkswagen AG
en AG. V
– Extract as much brake fluid as possible using suction
olks
wag hose does
not
from brake filling and bleeding equipment e-VAS
d by V 5234- . gu
ara
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utho eo
ra
a
WARNING ss c
ce
le
un
pt
Do not reuse extracted (used) brake fluid!
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
a
com
tio
– Fit brake pedal actuator -V.A.G 1869/2- between driver seat
n in
r
te o
do
cum
fo
t.
yi Co
Cop py
t. rig
gh ht
Note pyri by
Vo
co lksw
by
cted agen
Prote AG.
Observe ⇒ operating instructions for brake filling and bleeding
equipment -VAS 5234- !
WARNING
5. Descriptions of work 97
Amarok 2011 ➤
Maintenance - Edition 10.2012
ce
le
un
pt
an
d
– Close bleeder valve and quickly operate foot pedal 10 to 15
itte
y li
times from stop to stop.
rm
ab
pe
ility
– Open bleeder valve and allow another 0.05 litre or 50 cm3 of
ot
wit
brake fluid to flow out. , is n
h re
hole
spec
– Close bleeder valve and push on cover cap.
es, in part or in w
t to the co
– Press clutch pedal rapidly several times.
– Remove caps from bleed valves of brake calipers.
rrectness of i
Changing brake fluid at rear.
l purpos
– Push collector bottle bleed hose -1- onto rear right bleed valve.
nform
ercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
98 5. Descriptions of work
Amarok 2011 ➤
Maintenance - Edition 10.2012
1)
un
y li
• Brake fluid quantity to be changed: approx. 1.0 to 1.15 litre
rm
ab
pe
wit
, is n
Final checks
h re
hole
spec
t to the co
a
com
do
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
5. Descriptions of work 99
Amarok 2011 ➤
Maintenance - Edition 10.2012
WARNING
AG. Volkswagen AG d
agen
♦ Brake fluid must under no circumstances come into con‐ w oes
olks not
yV gu
tact with fluids containing mineral oils (oil, petrol, cleaning sed b ara
nte
solutions). Mineral oils will damage seals and sleeves tof ho
ri eo
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5.13.1 Checking brake fluid level at delivery in‐
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At delivery inspection the fluid level must be at MAX. marking
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If fluid level is below MIN marking -2-, the brake system must
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t to the co
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temperature for the left-hand and right-hand sides of the inte‐
l purpos
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windows do not work after the batteries have been discon‐
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spec
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♦ Therefore, with immediate effect, before a new vehicle is de‐
livered, the window regulators must be reactivated.
♦ Once the windows have been repositioned, the batteries must
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not be disconnected again.
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– Insert key in driver's door lock and lock vehicle from outside.
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5.16 Vehicle diagnosis tester
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♦ Connect vehicle diagnostic, testing and information system -
VAS 5051B- or vehicle diagnostic and service information
system -VAS 5052 A- and select functions ⇒ page 102
Or
♦ Diagnosis cable -VAS 5051/5A-
Or
♦ Vehicle diagnostic and service information system -VAS 5052
A-
♦ Diagnosis cable, 2 m -VAS 5052/3 A-
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t to the co
diagnosis or CAN communication.
♦ For a road test use diagnostic cable -VAS 5051/5A- , to guar‐
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antee the voltage supply of the vehicle diagnostic, testing and
information system -VAS 5051B- .
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event memory.
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AG.
♦ Brand
♦ Type
♦ Model year
♦ Version
♦ Engine code
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firm with > button.
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information system -VAS 5051B- or vehicle diagnosis and
service information system -VAS 5052 A- on how to proceed
for “Guided find finding” or “Guided functions”.
– End the system test via function GoTo and End or continue
“Guided fault finding” after changing the operating mode.
Caution
Static faults
If one or more static faults have been stored in the event memory,
it is advisable to rectify these faults with the help of “Guided trou‐
bleshooting” in consultation with the customer.
Sporadic faults
If only sporadic faults or notes have been stored in the event
memory
and the customer makes no complaints regarding an electronic
vehicle system, the event memory is to be erased.
Clear event memory.
– Start operating mode Vehicle self-diagnosis in system
start screen of vehicle diagnosis, testing and information sys‐
tem -VAS 5051B- or vehicle diagnosis and service information
system -VAS 5052 A- .
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♦ During the road test, take another person with you who
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VAS 5051B- or vehicle diagnosis and service information
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5.20 Dust and pollen filter: Clean housing and ir se
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Before installing the new filter, clean area around the dust and
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Removing
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The filter is located in front passenger footwell.
Perform the following jobs:
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– Unscrew bolts -1- and open cover -2- downwards.
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Installing
Perform the following jobs:
Note
AG. Volkswagen AG d
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5.22 Poly V-belt: Renew
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– The procedure is described in workshop manual ⇒ Rep. gr.
13 .
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To ensure the engine starts immediately after changing the fuel
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5.24 Fuel system: Bleed (diesel engine)
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Using vehicle diagnostic, testing and information system -VAS
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on in
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VAS 5051B- or vehicle diagnostic and service information
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system -VAS 5052 A- with ignition switched off ⇒ page 102 .
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– Switch on ignition.
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– Press the Guided functions button on the display.
– Then perform vehicle identification.
– Select following functions one after another:
♦ “Systems capable of self-diagnosis”
♦ “Diesel direct injection and glow plug system”
♦ “Functions”
♦ “Bleeding fuel system”
– Follow instructions on display of vehicle diagnostic, testing
and information system -VAS 5051B- or vehicle diagnostic
and service information system -VAS 5052 A- .
– After bleeding fuel system, exit “Guided functions” using Go-
To button.
– Screw drain plug back in, if necessary first fitting it with a new
seal if the old one was damaged.
Note
Caution
Note
♦ From model year 2008 all engines are filled with coolant ad‐
ditive G 12 Plus Plus (purple). G 12 Plus Plus can be enmixed
AG. Volkswagen AG d
with coolant additives G 11 (green), G 12 (red) Voland
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that only G 12 Plus is used when replenishing.
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and all-aluminium engines and gives optimum protection
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♦ G 12 Plus Plus raises the boiling point and ensures better heat
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hole
spec
tection to -40 °C). Otherwise both frost protection and cooling
es, in part or in w
t to the co
efficiency will be reduced.
♦ Frost protection must be assured to about -25 °C (in arctic
climatic countries to about -35 °C). rrectness of i
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Note
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climatic countries to about -35 °C).
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reasons, the percentage of G 12 Plus Plus can be increased.
rrectne
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s
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Frost protection to °C Quantity to drain (in litres)
Actual value Specified value 4-cylinder diesel engine
0 -25 3.5
-35 4.5
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-35 4.0
-10 -25 2.5
-35 3.5
AG. Volkswagen AG d
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5.26.2 Mixing coolants or eo
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Initial filling / standard filling
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with …
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G11 X 0 0 0
G12 0 X 0 0
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5.26.4 Mixture ratio
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♦ When replacing air filter, make sure that no dirt gets into intake
hose, air mass meter -G70- and air filter cover.
♦ Following each air filter change, programmed values of engine
control unit -J623- must be reset using Guided fault finding
with vehicle diagnostic, testing and information system -VAS
5051B- or vehicle diagnostic and service information system
-VAS 5052 A- ⇒ page 121 .
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G42- and connector -2- onto air mass meter -G70- .
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5.29 Resetting programmed values in engine
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– Follow menu instructions to reset programmed values of en‐
gine control unit -J623- .
– Switch off ignition and disconnect vehicle diagnostic, testing
and information system -VAS 5051B- or vehicle diagnostic
and service information system -VAS 5052 A- .
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-B- Oil may be replenished. It may happen that the
on
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or
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There is a danger of damaging the catalytic converter if the oil
t. C rig
gh ht
yri
level is above the -A- marking. p by
co Vo
by lksw
cted agen
– If the oil level is below the -C- mark, replenish oil up to the Prote AG.
-A- mark.
ce
e
nl
pt
5.31.1 Draining or extracting engine oil
du
an
itte
y li
erm
ab
ility
ot p
Note
wit
, is n
h re
hole
spec
For engines with standing oil filter the oil filter must be renewed
es, in part or in w
before changing the engine oil. When removing the filter element
t to the co
a valve is opened, the oil in the filter housing automatically flows
into crankcase.
rrectness of i
Special tools and workshop equipment required
l purpos
nform
ercia
at
om
ion
Draining or extracting engine oil
c
in t
or
his
ate
do
priv
c
Note
um
for
en
ng
t.
yi Co
op
For engines with standing oil filter the oil filter must be renewed C py
t. rig
before changing the engine oil. When removing the filter element
gh ht
pyri by
a valve is opened, the oil in the filter housing automatically flows
co Vo
by lksw
cted
into crankcase.
agen
Prote AG.
Note
The oil drain plug and seal are one unit and must be renewed
together.
– Screw in oil drain plug together with seal hand-tight and then
tighten to specified torque.
Specified torques for oil drain plug
♦ Diesel engines: 30 Nm
♦ Petrol engines: 30 Nm
WARNING
Removing
Perform the following jobs:
Note
pt
an
d
itte
ab
Installing
ility
ot p
wit
is n
spec
t to the co
Specified torque: 25 Nm
o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Note
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Or
nform
ercia
a
com
tion in
♦ Oil spill cloth -VAS 6204/1-
r
te o
thi
s
iva
Or
do
r
rp
cum
fo
t.
yi Co
op
Removing C py
t. rig
gh ht
yri
Perform the following jobs:
p by
o Vo
by c lksw
cted agen
– Loosen oil filter -arrow- with oil filter tool -VAS 3417- and re‐
Prote AG.
move filter.
– Clean sealing surface for example with universal cloth -VAS
6385- .
Installing
Perform the following jobs:
– Oil rubber seal lightly on new oil filter.
– Screw on new filter and tighten.
Specified torque: 22 ± 2 Nm
ce
le
5.31.5 Replenishing engine oil
un
pt
an
d
itte
y li
VW engine oil standards
erm
ab
ility
ot p
Engine oil capacities see ⇒ Engine lubrication; Rep. gr. 17
wit
is n
h re
General notes
ole,
spec
urposes, in part or in wh
Perform the following jobs:
t to the co
– After replenishing with oil, wait at least 3 minutes and then
check oil level.
rrectne
Note
ss o
cial p
f i
It is absolutely necessary to perform oil level check with the en‐
nform
gine warm in order to ensure correct assessment of the oil level.
mer
atio
om
n
c
– Pull out dipstick, wipe with a clean cloth and push dipstick in
i
or
n thi
again to limit stop.
te
sd
iva
o
pr
c
– Pull dipstick out again and read oil level.
um
r
fo
en
ng
t.
For dipstick as illustrated:
yi Co
Cop py
t. rig
gh
-A- Oil must not be replenished.
ht
pyri by
Vo
co lksw
-B- Oil may be replenished. It may happen that the
by
cted agen
Prote
oil level afterwards is in the -A- region.
AG.
Note
ce
e
nl
pt
5.33 du Bonnet catch: Clean, ensure attach‐
an
itte
y li
erm
ab
ility
ot p
wit
Special tools and workshop equipment required
, is n
h re
hole
spec
es, in part or in w
t to the co
– Clean bonnet catch -arrow- with cleaning solution -D 009 401
04- and, for example, a universal cloth -VAS 6385- . Also use
rrectness of i
“compressed air” to clean if necessary.
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
– Screw cleaned bolt back in hand-tight and then tighten firmly
yi Co
op py
to prescribed torque. t. C rig
gh ht
pyri by
Specified torque: 25 Nm
co Vo
by lksw
cted agen
Prote AG.
– Then unscrew second bolt -1- and clean contact surfaces
-arrows- with cleaning solution -D 009 401 04- and, for exam‐
ple, universal cloth -VAS 6385- .
– Screw second cleaned bolt back in hand-tight and then tighten
firmly to prescribed torque.
Specified torque: 25 Nm
Note
Caution
If the tyre filler bottle with sealant was opened e.g. at a "flat
tyre", it must be renewed.
Note
. Volkswage
♦ Residual tyre sealant
ksw
agenor bottles which
AG
are
n AG d
oesfilled and the expiry
date has been y V exceeded, must be disposed tof.
ol n o g
ua
db ran
ir se
♦ Old tyreth sealant or residual sealant must not be mixed
o tee
or and
disposed
ss
au
of with other fluids. ac
ce
le
un
pt
y li
ab
wit
is n
h re
spec
urposes, in part or in wh
f i
n
c
n thi
e
sd
va
roller dynamometer.
i
o
pr
cum
r
fo
en
ng
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
and if necessary, if anti-theft wheel bolts are installed: rrectness of i
l purpos
Or
rm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
ce
le
un
pt
proof wheel bolts -T10101- or adapter set for tamper-proof wheel
an
d
itte
bolts -T10190-
y li
rm
ab
pe
ility
ot
– Push adapter -2- into anti-theft wheel bolt -1- onto stop.
wit
, is n
h re
– Push wheel brace onto adapter -2- onto stop.
hole
spec
es, in part or in w
t to the co
Screw in wheel bolts hand-tight and then tighten to prescribed
torque setting.
rrectness of i
l purpos
Note
nform
ercia
a
com
tion in
Specified torque: 180 Nm
r
te o
thi
s
iva
– Place puller hooks and adapter with vehicle tool kit after com‐
do
r
rp
c
pleting work.
um
fo
en
ng
t.
yi Co
op
5.37 Reading radio code
C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
Only valid for vehicles without sticker with serial number and radio
code on vehicle data sticker.
Note
– Switch on ignition.
– Press the Guided functions button on display of vehicle di‐
agnostic, testing and information system -VAS 5051B- or ve‐
hicle diagnostic and service information system -VAS 5052
A- .
– Press > button to confirm selection.
– Then perform vehicle identification on vehicle diagnostic, test‐
ing and information system -VAS 5051B- or vehicle diagnostic
and service information system -VAS 5052 A- .
– Select one after another:
♦ Brand
♦ Type
♦ Model year
♦ Version
♦ Engine code
– If the vehicle identification has been performed correctly, con‐
firm with > button.
– Select one after another:
♦ Radio system
♦ Reading radio code
– Follow instructions of vehicle diagnostic, agen testing and informa‐
AG. Volkswagen AG d
oes
tion system -VAS 5051B- or vehicle olksw diagnostic and service not
y V gu
information system -VAS 5052 ise
d b
A- to read the radio code ac‐ ara
nte
cording to “Guided functions”.
ut
hor eo
r
sa ac
Exit radio code reading sas follows:
ce
le
un
pt
y li
erm
ab
wit
is n
spec
vehicle.
t to the co
Note
rrectne
atio
m
n
c
n thi
sd
va
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
ce
e
pt
du
an
itte
y li
erm
ab
ility
Note
ot p
wit
, is n
h re
♦ To read the radio code the radio serial number must be en‐
hole
spec
tered fully. This can be entered using vehicle diagnostic, test‐
es, in part or in w
t to the co
and service information system -VAS 5052 A- via “Guided
functions” and “Measured value block 81”. For this follow in‐
structions of vehicle diagnostic, testing and information sys‐
rrectness of i
tem -VAS 5051B- or vehicle diagnostic and service informa‐
tion system -VAS 5052 A- .
l purpos
nf
ercia
orm
♦ If you are authorized to read the radio code via “GeKo” (se‐
m
atio
m
n in
c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
Note
t.
yi Co
Cop py
t. rig
gh
Inform the customer about the radio code.
ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
5.38 Radio / radio navigation system: Enter
anti-theft coding PIN
The anti-theft coding electronically prevents unauthorized per‐
sons from operating the unit after it has been removed from
vehicle. The anti-theft codes are also called radio codes or se‐
curity codes. Security code means that each unit with an anti-theft
coding is programmed with its own code number. This security
code is not active when leaving the factory. The security code is
found on the unit card, if fitted. If the unit card is not fitted, the
security code can be read from a central database using vehicle
diagnosis tester.
ce
le
un
pt
an
d
itte
y li
Note erm
ab
ility
ot p
wit
If an incorrect code number is entered when releasing the elec‐
is n
h re
tronic lock, the whole procedure can be repeated once. If an
ole,
spec
incorrect code number is entered again, the unit is locked for
urposes, in part or in wh
about one hour. That means, it cannot be used. After one hour,
t to the co
during which time the unit must remain switched on, the display
extinguishes. The electronic lock can be released as described
above. The cycle, two attempts, one hour lock, applies again.
rrectne
Procedure
ss o
Deactivating anti-theft coding ⇒ Infotainment; Rep. gr. 91 .
cial p
f inform
5.39 Radio navigation system: Insert naviga‐
mer
atio
m
n
c
i
or
n thi
e
sd
va
o
pr
cum
r
DVD is inserted.
fo
en
ng
t.
yi Co
In this case, insert the navigation CD/DVD according to ⇒ Oper‐ t. Cop py
ating instructions .
rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
When the navigation CD is inserted the first time, the radio navi‐
gation system performs an update, which can take up to 5 mi‐
nutes. During this process, the radio navigation system must not
be pulled of and the ignition key must not be removed, otherwise
the navigation system switches off and the update will be inter‐
rupted!
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
Read precise value for the following tests at bright/dark boundary.
Using a pipette, place a drop of water on the glass to improve the
l purpos
nform
ercia
a
com
tio
– Check concentration of antifreeze additive using refractometer
n in
r
-T10007- (note).
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
le
un
pt
Starting immediately, use only Genuine Volkswagen Windscreen
an
d
itte
y li
rm
ab
window wash/wipe system.
pe
ility
ot
wit
, is n
h re
Note
hole
spec
es, in part or in w
♦ On vehicles with fan-type spray jets, the reservoir must be fil‐ t to the co
led with Windscreen Clear with antifreeze G 052 164, as this
fluid has a low viscosity at temperatures below freezing. Oth‐
rrectness of i
a
com
164 protects the spray jets, fluid reservoir and connecting ho‐
ion in
thi
s
iva
powerful cleanser removes wax and oil residue from the glass.
en
ng
t.
yi Co
op
♦ Frost protection must be guaranteed to approx. -25 °C (ap‐
C py
t. rig
gh
prox. -35 °C in countries with an arctic climate) in the wind‐
ht
pyri by
Vo
o
screen wash/wipe system. by c lksw
cted agen
Prote AG.
Note
ce
e
nl
pt
du
an
itte
y li
erm
ab
♦ “Clockwise” lower.
ility
ot p
wit
, is n
♦ “Anti-clockwise” higher.
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
m
n in
or c
position
thi
te
sd
iva
o
r
rp
cu
♦ Windscreen wiper blades: Check park position ⇒ page 137 .
o
m
f
en
ng
t.
yi
5.42.1 Windscreen wiper blades: Check park
Co
Cop py
t. rig
position
gh ht
pyri by
Vo
co lksw
by
cted agen
Windscreen of LHD vehicles Prote AG.
Note
For RHD vehicles the wiper blades are aligned as a mirror image.
Driver side
Perform the following jobs:
– Check park position.
Wiper blade tips should be located at marked position -arrow- on
windscreen.
– Adjust park position by moving wiper arm if necessary.
Adjusting windscreen wiper blades ⇒ Electrical system; Rep. gr.
92 ; Windscreen wiper blades - park position .
Front passenger side
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
Or
hole
spec
es, in part or in w
tio
thi
do
with a full fuel tank (at least 90 %) including weight of all equip‐
r
rp
cum
fo
ment normally carried (e.g. spare wheel, tools, jack, fire extin‐
en
ng
t.
guisher etc.).
yi Co
Cop py
ht. rig
If the fuel tank is not at least 90 % full, then load as follows: rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
ce
e
nl
pt
du
an
itte
y li
erm
ab
fuel gauge in kg
ility
ot p
1/4 30
wit
, is n
h re
1/2 20
hole
spec
3/4 10
es, in part or in w
t to the co
Full 0
Example:
rrectness of i
When the fuel tank is half full, an additional weight of 20 kg must
l purpos
nform
ercia
Note
m
at
om
ion
♦ A fuel can filled with water is the best way of adding additional
c
in t
or
weight.
his
ate
do
riv
cum
for
en
ng
t.
yi Co
The vehicle must be rolled forward or backward several metres Cop py
t. rig
or front and rear springs must be bounced fully several times so gh ht
yri by
that springs settle.
op Vo
by c lksw
cted agen
Prote AG.
♦ Vehicle and headlight adjuster must be on a level surface ⇒
of headlight adjustment unit -VAS 5046- or ⇒ of headlight ad‐
justment unit -VAS 5047-
♦ Vehicle and headlight adjuster must be aligned.
♦ Inclination must be set.
Inclination information in “%” is stamped into trim above headlight.
Headlights must be adjusted according to this information. Per‐
centage given is based on a projection distance of 10 metres. For
example: inclination of 1.0 % converts to approx. 10 cm.
Vehicles with manually regulated headlight range control
♦ Headlight range control thumb wheel must be in basic setting
-0-.
The bright core of the light beam must be to the right of the vertical
line.
Note
screen.
pt
du
an
itte
y li
ab
ility
ot p
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Left headlight
ercia
orm
m
n in
c
thi
te
sd
a
The adjustment bolts for the right headlight are a mirror image.
iv
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
le
Adjustment screw for setting fog lights can only be accessed from
un
pt
an
d
rear.
itte
y li
rm
ab
Perform the following jobs:
pe
ility
ot
wit
, is n
h re
hole
spec
A lateral adjustment is not possible.
es, in part or in w
t to the co
Other additional lights
Additionally retrofitted lights of other systems must be checked
and set according to valid guidelines.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
do
r
rp
cum
en
g
t.
yi Co
Cop py
Resetting service interval display using VAS vehicle diagnosis
t. rig
gh ht
yri by
tester software ⇒ page 142 cop Vo
by lksw
cted agen
Prote
The service interval display must be reset when the following is
AG.
carried out:
♦ Delivery inspection
♦ Every oil change service and interval service.
Note
pt
an
d
y li
erm
ab
wit
is n
spec
on the ignition.
t to the co
»Accept«.
s o
cial p
f i
– Select control unit, dash panel insert and select »Guided func‐
nform
atio
m
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
ce
le
un
pt
an
d
itte
Note
y li
erm
ab
ility
ot p
♦ It is not necessary to log in in order to enter or call up vehicle
wit
is n
data.
h re
ole,
spec
♦ If the options indicated in the working procedure are not shown
urposes, in part or in wh
on the display ⇒ Operating instructions for vehicle diagnosis
t to the co
tester
rrectness
Caution
o
cial p
f inform
♦ Diesel engines: In some regions/countries, an elevated
mer
atio
om
n
c
i
or
n
cleanliness considerably. Short service intervals therefore
thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
Note
gh ht
pyri by
Vo
co lksw
by
cted agen
♦ With this function, the service interval display is adapted for
Prote AG.
End adaptation.
– Confirm end of interval adaptation with the »Done« button.
– Exit “Guided functions”.
– Switch off ignition and separate diagnosis connections.
ce
le
moving track rods and wheels:
un
pt
an
d
itte
Clearance: Zero clearance
y li
erm
ab
ility
– Check mountings.
ot p
wit
is n
– Check that boots -arrow- are not damaged and are seated
h re
ole,
correctly.
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
e
sd
iva
o
pr
c
level
um
r
fo
en
ng
t.
yi Co
♦ Oil at operating temperature ⇒ page 145 Cop py
t. rig
gh ht
yri
♦ Fluid cold ⇒ page 144 p by
co Vo
by lksw
cted agen
5.47.1 Fluid cold
Prote AG.
Test prerequisites
• Engine switched off
Perform the following jobs:
– Unscrew sealing cover -arrow- with built-in dipstick from tank.
– Wipe off dipstick using a clean cloth.
– Screw sealing cover on until finger tight and then unscrew
again. Following this, fluid level can be checked.
The oil level must be in the area of the “20°C” mark.
Note
♦ If the fluid level is above the area specified, the excessive fluid
must be extracted.
♦ If the oil level is below the area specified, the hydraulic system
must be checked for leaks (repair measure) and, if necessary,
topped up with hydraulic oil -G 002 000- .
ce
e
nl
pt
du
an
itte
Note
y li
erm
ab
ility
ot p
♦ If the fluid level is above the area specified, the excessive fluid
wit
, is n
must be extracted.
h re
hole
spec
♦ If the oil level is below the area specified, the hydraulic system
es, in part or in w
t to the co
topped up with hydraulic oil -G 002 000- .
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
c
thi
e
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
ce
le
un
pt
♦ Faults found must always be rectified (repair measure). There‐
an
d
itte
y li
fore, further damage and corrosion and rusting through can be
rm
ab
avoided.
pe
ility
ot
wit
, is n
h re
5.50 Protective foil: Remove (if fitted)
hole
spec
es, in part or in w
t to the co
Note
rrectness of i
The foil must “NOT” be removed from the rear bumper on Amarok
models in “Russia” with chrome bumpers.
l purpos
Reason:
nform
ercia
a
This aggressive substance could corrode the chrome coating.
com
tion in
r
thi
s
iva
do
r
rp
cum
fo
en
g
During visual check, also check floor pan, wheel housings and
n
t.
yi Co
op
sills. C py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Note Prote AG.
Note
Clock -B- can only be set when the time is displayed in the dash
panel insert -K- and is not overlaid with another display.
– Pressing 0.0 / SET -A- for longer changes hour value quick‐
ly.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
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du
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ab
ility
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, is n
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spec
es, in part or in w
t to the co
5.53 Camshaft drive toothed belt and toothed
rrectness of i
belt tensioning roller: Renew
l purpos
nform
mercia
at
om
ion
dition
c
in t
or
his
ate
Applicable to
do
priv
cum
for
t.
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op
♦ Diesel engines
C py
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Perform the following jobs: cop Vo
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– Remove toothed belt guard ⇒ Rep. gr. 15 .
– Check toothed belt condition, looking for:
♦ -A- Cracks, cross-sectional breaks, cracks (coating)
♦ -B- Side contact
♦ -C- Fraying of cord strands
♦ -D- Cracks (in teeth base)
♦ Layer separation (toothed belt body, draw strands)
♦ Surface cracks (synthetic coating)
♦ Traces of oil and grease
Note
If faults are found always renew toothed belt. This will avoid pos‐
sible breakdowns or operating problems. The replacement of a
toothed belt is a repair measure.
Note
. Volkswagen AG
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♦ Spark plug socket y V and extension -VAS 3122B- t gua
olk no
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au ac
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du
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ab
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spec
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♦ Puller -T40039-
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mercia
at
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ion
c
in t
or
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ate
do
priv
cum
for
en
ng
t.
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Cop py
ht. rig
rig ht
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co Vo
by lksw
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Prote AG.
Removing
Perform the following jobs:
– Pull out all ignition coils with final output stage from cylinder
head approx. 30 mm using puller -T40039- .
pt
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itte
ab
ility
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wit
, is n
Note
h re
hole
spec
t to the co
– Evenly push ignition coils with final output stages onto spark
plugs by hand.
rrectness of i
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nform
ercia
at
om
in t
or
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ate
do
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Note
p
cum
for
en
ng
t.
Get a second mechanic to help you to remove and install skid
yi Co
op
plate.
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by lksw
Perform the following jobs: Prote
cted AG.
agen
Note
AG. Volkswagen AG d
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du
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ab
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wit
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spec
es, in part or in w
t to the co
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nf
ercia
orm
m
atio
om
n in
or c
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sd
iva
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cu
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t.
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Cop py
t. rig
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pyri by
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by c lksw
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Prote AG.
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nl
pt
du
an
The following exhaust emissions test description is applicable
itte
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ab
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have to be adhered to.
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spec
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engine:
♦ 3 years after initial registration and then every 2 years.
rrectness of i
♦ Vehicles for commercial passenger transport, e.g. taxis: every
l purpos
12 months
General for exhaust emissions test ⇒ page 152
nform
ercia
Exhaust emissions test for petrol engines with engine code CFPA
m
at
⇒ page 153
om
ion
c
in t
Exhaust emissions test for diesel engines with engine codes
or
his
e
do
priv
cum
Exhaust emissions test with OBD ⇒ page 163
for
en
ng
t.
yi
6.1 General information for exhaust emis‐
Co
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Note
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6.2 Exhaust emissions test for petrol en‐
itte
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ab
gines with engine code CFPA
ility
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wit
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spec
Note
urposes, in part or in wh
t to the co
♦ The following description refers to vehicles fitted with “On‐
board diagnosis” (OBD) and regulated catalytic converter.
rrectne
♦ The OBD monitors all components and part systems influenc‐
ing the exhaust emissions quality.
ss o
cial p
Special tools and workshop equipment required
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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o
pr
cum
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fo
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t.
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Cop py
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Vo
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by
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Prote AG.
Note
Test prerequisites
• All test conditions and data required for exhaust emissions test
⇒ Data sheets for exhaust emissions test for respective engine
• For bar code reading the EET data sheet must be printed out.
• Manual gearbox: Gear lever in neutral
• Handbrake pulled on
– Perform exhaust emission test according to instructions on
display.
Initial screen
– Select Exhaust emissions test -arrow- button.
An overview is displayed to select the respective EET type.
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
tion in
thi
s
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do
cum
fo
en
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t.
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Cop py
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♦ -4- Key number to 3 (old) or 2.2 (new): “e.g. 358”
an
d
itte
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♦ -5- Engine code “e.g. CFPA”
rm
ab
pe
ility
ot
h re
♦ -7- Vehicle identification number: “e.g.
hole
spec
WV1ZZZ2HZYW123456”
es, in part or in w
t to the co
Note
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a
com
tion in
thi
s
do
r
rp
cum
fo
en
ng
t.
yi
Note
Co
Cop py
t. rig
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♦ If specifications are not available as bar code, they are to be
cop Vo
by lksw
entered manually. cted agen
Prote AG.
♦ All test conditions and data required for exhaust emissions test
⇒ Data sheets for exhaust emissions test for respective engine
ce
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nl
pt
button -arrow-.
du
an
itte
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erm
ab
Specified data input for EET as bar code:
ility
ot p
wit
, is n
h re
bar code of EET data sheet using reader pen.
hole
spec
es, in part or in w
t to the co
– Press ► -button- to continue procedure.
rrectness of i
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nf
ercia
orm
m
atio
m
Visual check
o
n in
or c
thi
te
sd
iva
o
– Perform visual checks.
r
rp
cu
o
m
f
en
ng
The visual check is displayed with the request to connect the di‐
agnosis connector -arrow A- and to check the MI lamp
-arrow B-.
– Follow instructions on display.
– Switch off ignition.
pt
du
an
itte
The exhaust emissions test is only continued when the test probe
y li
erm
ab
wit
, is n
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hole
t to the co
Note
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♦ If not all display values have been set to “0”, a regulating probe
m
at
om
in t
or
his
ate
-arrow B-.
cum
for
en
ng
t.
Catalytic converter conditioning
yi Co
Cop py
ht. rig
It is automatically switched to warm-up phase of catalytic con‐ rig ht
py by
verter. co Vo
by lksw
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Prote AG.
Warm-up phase
It is automatically switched to display for measuring engine tem‐
perature.
. Volkswagen AG
– Follow instructions on
swadisplay.
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du
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reached 80 ℃.
itte
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ab
ility
ot p
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hole
idling speed.
– Follow instructions on display.
rrectness of i
Measurement starts when the engine speed has reached the re‐
l purpos
quired level.
nform
ercia
Note
m
at
om
io
in t
or
do
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♦ Measured values are reset using the ← button and the test can
p
cum
or
be repeated.
f
en
ng
t.
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Cop py
. rig
– Keep engine speed within required rpm range.
ht ht
rig by
copy Vo
The remaining time to perform measurement is displayed
by lksw
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-arrow A-.
AG.
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ab
values have been set to “0”.
pe
ility
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wit
, is n
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It is automatically switched to display for regulating probe test.
hole
spec
es, in part or in w
t to the co
Note
rrectness of i
individually.
l purpos
Measurement starts when the engine speed has reached the re‐
quired level.
nform
ercia
a
com
tio
-arrow A-.
thi
s
iva
do
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rp
cum
Evaluation
fo
en
ng
t.
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When the exhaust emissions test has been performed, the log is
Co
Cop py
shown on display. ht. rig
rig ht
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The test result is displayed.
by c lksw
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Prote AG.
Now remarks concerning the exhaust emissions test can be en‐
tered -arrow A-. These will then be included in the test log.
– When the exhaust emissions test is classed as passed, select
-arrow B- EET sticker issued in drop-down menu and date.
– Then confirm with Yes , see -arrow C-.
AG. Volkswagen AG d
agen oes
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byV gu
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aut ra
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nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
ion
c
in t
or
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te
Note
a
do
priv
cum
for
To reach the engine revs limit, the TCS and ESP button -E256-
en
ng
t.
yi Co
has to be pressed. . Cop py
rig
ht ht
rig by
copy Vo
by lksw
cted agen
Prote
Note
AG.
♦ All test conditions and data required for exhaust emissions test
⇒ Data sheets for exhaust emissions test for respective engine
♦ If possible, the test should be completed outdoors following a
road test. If this is not possible for various reasons (weather,
excessive noise in residential areas), then the test can be car‐
ried out in a workshop.
♦ To reduce noise levels, the bonnet should be closed on first
catch during tests.
♦ Leakage
♦ Damage
Note
Note
pt
du
y li
ab
wit
h re
spec
Note
m
at
om
ion
c
The idling speed and maximum speed can be checked but not
in t
or
adjusted.
his
ate
do
priv
cum
or
en
ng
t.
must be made.
yi Co
Cop py
t. rig
Performing acceleration test.
gh ht
pyri by
Vo
co lksw
by
– Press “button for acceleration test”. cted agen
Prote AG.
WARNING
ce
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pt
n rpm tB s k 1/m Gas T °C M
an
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itte
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erm
ab
The arrow pointing upwards indicates that the unit is waiting for
ility
ot p
wit
is n
h re
ole,
In this way, the unit measures and registers at least four throttle
rrectne
bursts. After the fourth and for each further throttle burst se‐
quence, an average of the last three measurements is performed.
ss
i
or
n thi
sd
a
cum
r
fo
en
t.
yi Co
another measurement is called up. t. Cop py
rig
gh ht
If the opacity figures are equal to or less than the prescribed fig‐ pyri by
Vo
o
by c
ures, cease measurements.
lksw
cted agen
Prote AG.
If the determined opacity figure is above the prescribed figure,
locate fault within repair measure framework ⇒ Fault finding en‐
gine
Note
ce
le
pt
an
d
itte
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erm
ab
must be performed ⇒ page 152 .
ility
ot p
wit
is n
h re
ole,
spec
♦ Vehicle diagnostic, testing and information system -VAS
urposes, in part or in wh
5051B-
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
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o
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fo
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op
♦ Vehicle diagnostic and service information system -VAS 5052
C py
t. rig
gh
A-
ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
– Pull on handbrake.
– Manual gearbox: Gear lever in neutral.
– Connect diagnosis cable connector to diagnosis connection
with ignition switched off.
AG. Volkswagen AG d
agen
– Connect vehicle diagnostic, testing and information
olks system -
w oes
not
yV gu
VAS 5051B- or vehicle diagnostic and serviceed
b information ara
nte
system -VAS 5052- ⇒ page 102 . ris
tho eo
au ra
– Switch on ignition. ss c
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f i
n
c
n thi
te
sd
a
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
tion system -VAS 5051B- or vehicle diagnostic and service
information system -VAS 5052- .
rrectne
Evaluation:
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
a
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pr
cum
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fo
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t.
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Note Cop py
t. rig
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pyri by
♦ Exhaust emissions test is PASSED when all “ACTUAL values”
o Vo
by c lksw
cted
correspond to “SPECIFICATIONS”.
agen
Prote AG.
Note
7 Glossary
These explanations only apply to “Maintenance Manual”. They
are not necessarily generally valid!
Letter “A” ⇒ page 166
Letter “B” ⇒ page 166
Letter “C” ⇒ page 166
Letter “D” ⇒ page 167
Letter “E” ⇒ page 167
Letter “F” ⇒ page 167
Letter “L” ⇒ page 167
Letter “M” ⇒ page 167
Letter “O” ⇒ page 167
Letter “P” ⇒ page 168
Letter “Q” ⇒ page 168
Letter “R” ⇒ page 168
Letter “S” ⇒ page 168
Letter “T” ⇒ page 168
Letter “W” ⇒ page 169
Letter “X” ⇒ page 169 agen
AG. Volkswagen AG d
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Letter “A” byV gu
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Term Explanation aut ra
ss c
All Season All-season tyres / all weather tyres All season tyres are all-year-round tyres. The tyres
ce
le
un
pt
are designed to cope with all weather conditions throughout the year.
an
d
itte
y li
rm
ABS The ABS is a regulating system in the brake system, that prevents locking when braking.
ab
pe
ility
(anti-lock brake This helps to maintain directional stability and steerability.
ot
wit
system)
, is n
mission fluid)
t to the co
Letter “B”
Term Explanation
nform
ercia
Broad-band probe The broad-band probe is also called universal lambda probe (ULP probe). The voltage
m
a
com
of the lambda probe output nearly increases linear. The lambda probe value is deter‐
ion in
mined by a change in voltage. This enables to measure the lambda probe value via a
r
te o
thi
larger measuring range (broad band). The probe is used as before catalytic converter
s
iva
probe.
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
.
Letter “C”
ht rig
rig ht
py by
co Vo
by lksw
Term Explanation cted agen
Prote AG.
C - tyres C-mark tyres are used as light truck tyres. Use correct inflation pressure when changing
from “Reinforced tyres” to “C-mark tyres”.
CARB requirement “California Air Resources Board” - measures to restrict airborne pollutants
166 7. Glossary
Amarok 2011 ➤
Maintenance - Edition 10.2012
Term Explanation
CO Carbon monoxide is produced when fuels containing carbon are not combusted com‐
(Carbon monoxide) pletely.
CN Measurement unit for ignition quality of diesel fuel
. Volkswagen AG
(Cetane number) swa
gen AG does
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Letter “D” au ra
c
ss
ce
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un
pt
Term Explanation
an
d
itte
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DPF The diesel particulate filter is installed behind the catalytic converter and filters soot
erm
ab
ility
(Diesel particulate particles from emissions.
filter) ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
Letter “E”
rrectne
Term Explanation
EN European standard
ss o
EOBD European onboard diagnosis
cial p
f inform
ESP Electronic stabilisation programme (prevents potential vehicle skidding by targeted in‐
mer
atio
om
n
c
i
or
n thi
te
sd
va
Letter “F”
i
o
pr
cum
r
fo
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ng
Term Explanation
t.
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Cop py
FAME Fatty acid methyl ester ht. rig
rig ht
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co Vo
by lksw
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Prote AG.
Letter “L”
Term Explanation
LongLife service The LongLife service enables extremely long inspection or oil change intervals, de‐
pending on individual driving style and the conditions under which the vehicle is used.
For the LongLife service a special engine oil is required.
LEV Low Emission Vehicle
Letter “M”
Term Explanation
M&S § 36 of StVZO (Germany's highway regulations) defines the identification of a winter tyre
as “M&S”.
MIL American designation for MI lamp -K83-
(Malfunction Indica‐
tor Light)
Letter “O”
Term Explanation
OBD The OBD monitors all components influencing the exhaust emissions quality.
(Onboard diagno‐
sis)
7. Glossary 167
Amarok 2011 ➤
Maintenance - Edition 10.2012
Letter “P”
Term Explanation
PR number Abbreviation for productionwcontrol
gen AG number. It
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G do among other things optional
s a es n
equipment, country-specific
y Volk deviations ot g
u b ara
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oris e
th or
au ac
ss
Letter “Q”
ce
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un
pt
an
d
Term Explanation
itte
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rm
ab
QG0 Vehicles are “not” fitted at the factory with components for LongLife service. For main‐
pe
ility
ot
wit
, is n
h re
QG1 Vehicles are fitted at the factory with active LongLife service. This means vehicles have
hole
spec
a flexible service interval display and are fitted with the following components:
es, in part or in w
t to the co
♦ Engine oil level sensor
♦ Brake pad wear indicator (if fitted)
rrectness of i
l purpos
QG2 The LongLife service is not active at the factory. This means, vehicles have a non-flexible
service interval display (time or distance dependent service intervals) and are fitted with
the following components:
nform
ercia
a
com
t
♦ Engine oil level sensor
ion in
r
te o
thi
s
iva
do
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rp
cum
fo
en
ng
t.
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op
Letter “R”
C py
ht. rig
rig ht
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Term Explanation
co Vo
by lksw
cted agen
Prote AG.
RON Measurement unit of the knock resistance of petrol
(Research Octane
Number)
RF “Reinforced”, reinforced tyre, additional designation for tyres with increased load ca‐
pacity
Letter “S”
Term Explanation
SAM (South Ameri‐ South America
can countries)
Step-type probe The step-type probe is also called finger probe or planar lambda probe. The voltage of
the output signal of the lambda probe jumps rapidly. The lambda probe value is deter‐
mined by a change in voltage. The probe is used as after catalytic converter probe.
Letter “T”
Term Explanation
TDI Turbo diesel engine with direct injection
(Turbo Diesel Injec‐
tion)
168 7. Glossary
Amarok 2011 ➤
Maintenance - Edition 10.2012
Letter “W”
Term Explanation
ESI Extended servicing interval
Letter “X”
Term Explanation
XL “Extra Load”, reinforced tyre, additional designation for tyres with increased load ca‐
pacity
n AG. Volkswagen AG do
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byV ua
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ir se tee
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nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
7. Glossary 169